Design and Implementation of Electrical Car with Manual Gear System

Abstract

This essay\\\'s main goal is to explain how to turn an outdated car with a petrol or diesel engine into an electric vehicle. An automobile is electric if its whole driving mechanism is an electric motor that is entirely powered by a battery pack. This car\\\'s unique characteristic is that it can be operated using the manual gearing system that the car already has. Our goal is to demonstrate a low-cost method for converting ageing vehicles to electric vehicles. The primary obstacles in developing an electric car are selecting a motor that is rated appropriately for the vehicle, considering the passengers, battery pack, chassis, and motor weights. Another task is selecting a battery that meet our project\\\'s financial objectives. The use of several gear ratios provides several possible advantages, such as enhancing vehicle acceleration, gradeability, and top speed, and reducing the overall mass and space of the traction system. Due to their high torque and power requirements, performance vehicles, light to heavy duty trucks, and buses may particularly profit from multi-speed gearboxes.

Introduction

I. INTRODUCTION

One of the best technologies for the future is the electric vehicle, which uses less fossil fuel and is more environmentally beneficial because it emits less dangerous pollutants. The charging module, converters, controllers, batteries, and electric motor are only a few of the numerous parts that make up an electric vehicle.

Figure 1 shows the block diagram of how power is distributed in an electric vehicle. The power supply can be obtained from domestic sources or from any charging stations, as shown in Figure 1. The battery is then given access to this power via an EV charger after it has been rectified using a converter. A motor controller aids in regulating the input and output characteristics of the motor, transfers electric power from the battery to the motor. With a drive shaft, the wheel receives the mechanical power the motor produces. In an electric car, mechanical power is created as a result of the electric current passing through various parts. As a result, the output parameters of a vehicle, such as its power, torque, speed, etc., are determined by an electric motor. In order to counteract the force caused by the load and other opposing forces operating on the vehicle, the electric motor chosen to drive it must be capable of producing enough power and torque. This paper deals with calculating the power rating required to drive an electric vehicle, and charging time of battery through an EV charger, along with its operation.

After removing any unnecessary components from the car, such as the fuel tank and the silencer, attach the engine to a 4-speed gearbox coupler and fit it to the gearbox using the pressure plate, clutch plate, and flywheel as shown Figure 2.

[5] By doing this, we can turn our combustion engine into an electrical one that runs faster and more efficiently while consuming less motor power. This vehicle has a 100ah controller, a 3000w PMSM motor, and series-connected lead-acid batteries with a 12V and 100ah capacity. The outcomes of our road testing of this car are excellent. The car has a gross weight of 800 kg, a motor that can lift up to 1100 kg of weight, a top speed of 60 km/h with 4 passengers, and a range of 50 to 60 kilometres due to the usage of lead acid batteries. [7] The manual gear mechanism raises the motor's rpm from 3000 to 6000 while also providing the fundamental torque required for movement. the movement of electricity produced by a solar panel array into a battery pack. A PMSM motor will thereafter be driven by the energy that was previously stored.

Conclusion

Here, the future is occupied by electric vehicles. They encourage further generations towards eco-friendly transport. As we have seen number of old cars becoming iron trash due to various internal faults. These types of cars can be renovated to the electric vehicle mentioned in this paper. They can be very useful in Urban transport of shorter distance and ca even reduce sound pollution to some extent.

References

[1] Prasun Mishra, Suman Saha, and H.P.Ikkurti,” A Methodology for Selection of Optimum Power Rating of Propulsion Motor of Three Wheeled Electric Vehicle on Indian Drive Cycle (IDC)”, in International Journal on Theoretical and Applied Research in Mechanical Engineering [IJTARME], Volume 2, Issue 1,pp. 96, 2013. [2] Sagar Tatipamula,”Study of Parallel Electric Hybrid Three - Wheeled Motor Taxi” in International conference on Green Computing and Technology 2013, under International Journal of Computer Applications (0975-8887), pp. 38-39. [3] Bekheira Tabbache, Soane Djebarri, Abdelaziz Kheloui, Mohamed Benbouzid,” A Power Presizing Methodology for Electric Vehicle Traction Motor”, in International Review on Modelling and Simulations, October 2013. [4] Amir Ahmed, Dikki D. Bhutia,” Propulsion System Design and Sizing of an Electric Vehicle”, in International Journal of Electronics and Electrical Engineering, Volume 3, No. 1, February 2015. [5] https://footprinthero.com/solar-panel-charge-time-calculator [6] J. Shen, S. L. Zheng, and J. Z. Feng,“Light weight design of gear sets in wheel driving deceleration system of electric vehicle: Modal frequency of updated Gear 4. Oder Intrinsic frequency (Hz) 1 1103.4 2 1208.5 3 1342.7 4 1668.1 5 1768.6 6 1797.2 Wireless Communications and Mobile Computing 11 based on load spectrum,” Journal of Mechanical Strength., vol. 39, no. 4, pp. 835– 841, 2017.

Copyright

Copyright © 2023 B. Srinivasa Rao, K. Eswara Rao, G. Naveen, B. Sai Vikas, P. Tejeswara Rao, R. Santhosh. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.