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E-Vehicle Assembly Training Course – A Complete Guide for Beginners and Advanced

INTRODUCTION TO ELECTRICAL VEHICLES

An Electric Vehicle (EV) is a vehicle that runs on an electric motor, powered by a rechargeable battery pack instead of a traditional internal combustion engine (ICE) that relies on fossil fuels such as gasoline or diesel. EVs use electricity stored in a battery to power the motor and move the vehicle, resulting in zero tailpipe emissions, making them an environmentally-friendly alternative to ICE vehicles.

History of Transport Systems

Transportation has come a long way since the invention of the wheel. Humans have utilized various modes of transport to cover long distances, from walking and animal-drawn carts to steam engines and automobiles. In the 21st century, the transportation sector has undergone a major shift towards sustainable and eco-friendly alternatives, one of which is the EV.

Current Need for EVs in the Indian Transport Market

India has the third-largest market for automobiles in the world, and with the increasing population, urbanization, and pollution, there is a dire need for sustainable and eco-friendly modes of transportation. EVs have the potential to address the country’s air pollution and oil dependency issues while promoting renewable energy sources.

Comparison between ICE and Power Drain

ICE vehicles rely on burning fossil fuels to generate energy, whereas EVs use electricity stored in batteries. The power consumption of an EV depends on the battery size, driving style, and terrain, among other factors. However, studies have shown that EVs are more energy-efficient than ICE vehicles, resulting in lower power consumption and lower emissions. Additionally, the cost of electricity is generally lower than gasoline or diesel, making EVs a more cost-effective option in the long run.

The rise of EVs is an important step towards sustainable and eco-friendly transportation. With the increasing demand for EVs in India and worldwide, it is likely that the future of transportation will be electric.

ELECTRIC VEHICLE TYPES

There are three main types of electric vehicles (EVs) available in the market today. These include:

  • Battery-Operated Vehicle

BEVs are also known as pure electric vehicles. These vehicles are powered solely by an electric motor and are powered by a rechargeable battery pack. Examples of BEVs include the Tesla Model S and the Nissan Leaf.

  • Hybrid Electrical Vehicle

HEVs use both an electric motor and an internal combustion engine to power the vehicle. Examples of HEVs include the Toyota Prius and the Honda Insight.

  • Fuel Cell Operated Vehicle

FCVs use hydrogen to power an electric motor. Examples of FCVs include the Toyota Mirai and the Honda Clarity.

Fundamentals components of Electrical 2 & 3 wheeler

  • Motors

The motor is the heart of an electric vehicle. It converts electrical energy into mechanical energy to drive the vehicle. In an electric 2 or 3-wheeler, the motor is usually mounted on the rear wheel hub.

  • Controller

The controller is responsible for controlling the speed and torque of the motor. It receives signals from the throttle and battery and adjusts the motor’s output accordingly.

  • Throttle

The throttle is used to control the speed of the vehicle. It is similar to the gas pedal in a conventional vehicle.

  • Battery

The battery is the power source of an electric vehicle. It stores the electrical energy required to power the motor. In an electric 2 or 3-wheeler, the battery is usually mounted under the seat.

  • DC to DC Convertor

The DC-to-DC converter converts the high-voltage DC power from the battery to the lower-voltage DC power required to power the lights, horn, and other electrical components of the vehicle.

  • Meters

The meters on an electric 2 or 3-wheeler provide information about the vehicle’s speed, battery level, and other critical information.

BASIC ELECTRICALS

Electrical Supply

An electrical supply is a source of energy that is used to power electrical devices. There are two types of electrical supply – AC (alternating current) and DC (direct current).

  • Fundamentals of AC Supply

AC supply is the most commonly used electrical supply. It consists of a waveform that alternates between positive and negative values. The frequency of the waveform is measured in Hertz (Hz). In most countries, the standard frequency of the AC supply is 50 Hz or 60 Hz.

  • Fundamentals of DC Supply

DC supply is a unidirectional current flow, where the flow of current is in a single direction. DC supply is often used in electronic devices, such as batteries and power supplies.

  • Difference between AC & DC

The main difference between AC and DC is the direction of current flow. In AC, the current changes direction periodically, whereas in DC, the current flows in only one direction. AC supply is commonly used for power transmission, while DC supply is used in electronic devices.

What are Voltage, Current, Power, and Energy?

Voltage is the potential difference between two points in an electrical circuit. It is measured in volts (V).

Current is the flow of electric charge in a circuit and is measured in amperes (A).

Power is the rate at which work is done and is measured in watts (W).

Energy is the ability to do work and is measured in joules (J).

What is Resistance?

Resistance is the property of a material that resists the flow of electric current. It is measured in ohms (Ω). The resistance of a material is dependent on its physical properties, such as the length and cross-sectional area of the material.

  • Series Connections

In a series connection, components are connected one after the other. The current in a series circuit is the same through all components, and the voltage is divided between the components based on their resistance.

  • Parallel Connections

In a parallel connection, components are connected in parallel with each other. The voltage in a parallel circuit is the same across all components, and the current is divided between the components based on their resistance.

  • Combination of Series & Parallel Connections

In some circuits, components are connected in both series and parallel. This is known as a combination circuit.

What are Transformers?

Transformers are electrical devices that are used to transfer electrical energy from one circuit to another through electromagnetic induction. Transformers work on the principle of mutual induction, where the change in the magnetic field induces an electromotive force (EMF) in a nearby conductor. Transformers are used for power transmission and distribution, and also for voltage regulation in electronic devices.

BASIC ELECTRICALS – PRACTICAL

Basic electrical connections are an essential aspect of electrical engineering. In this context, we can distinguish three main types of connections: series, parallel, and a combination of both. Understanding these connections is essential for designing and building circuits in practice.

  • Series Connections

In series connections, the components are connected end-to-end such that the current flows through each component in sequence. A series connection creates a single path for the current to flow through, which means that the same current flows through each component in the circuit.

The voltage in a series circuit is divided among the components based on their resistance. Therefore, the total resistance of the circuit is equal to the sum of the resistance of each component. In other words, if we connect a 10-ohm resistor and a 20-ohm resistor in series, the total resistance of the circuit would be 30 ohms.

  • Parallel Connections

In a parallel connection, the components are connected side by side such that the current can flow through each component independently. The voltage across each component in a parallel connection is the same.

In a parallel connection, the total current is divided among the components based on their resistance. Therefore, the total resistance of the circuit is calculated differently compared to a series circuit. In a parallel circuit, the total resistance is the reciprocal of the sum of the reciprocals of each component’s resistance. For instance, if we connect a 10-ohm resistor and a 20-ohm resistor in parallel, the total resistance of the circuit would be 1/((1/10)+(1/20))=6.67 ohms.

  • Combination of Series & Parallel Connections

In practice, circuits are often a combination of both series and parallel connections. In such circuits, the individual components are connected in both series and parallel to achieve the desired circuit properties.

For example, if we connect three resistors, one in series and the other two in parallel with the first resistor, we would create a combination circuit. The total resistance of this circuit is the sum of the resistance of the resistor in series and the resistance of the parallel combination of the other two resistors. Thus, the total resistance of the circuit can be calculated as follows:

Total resistance = 10 + 1/((1/20)+(1/30)) = 16.67 ohms.

Understanding the basics of electrical connections is essential for designing and building circuits in practice. Series and parallel connections are two fundamental types of circuits that are used alone or in combination to achieve the desired circuit properties.

BASIC ELECTRONICS – Part 1

What is Electronics?

Electronics is a branch of physics that deals with the study of electrons and their behaviour in electronic devices. It involves the manipulation of electrons to create, control, and transmit information, as well as to provide power to electronic devices. Electronics have revolutionized the modern world, providing us with computers, smartphones, televisions, and many other devices that we rely on daily.

Basic Electronics Components

There are many components used in electronics, but some of the most basic and important ones include diodes, transistors, and MOSFETs.

Diode

A diode is a two-terminal electronic component that allows current to flow in one direction while blocking it in the opposite direction. It is made up of semiconductor materials, such as silicon or germanium, with a p-type (positive) and an n-type (negative) region. When a voltage is applied across the diode, it allows current to flow from the p-type region to the n-type region, but not the other way around. Diodes are used in rectifiers, voltage regulators, and signal demodulators, among other applications.

Transistor

A transistor is a three-terminal electronic component that can amplify or switch electronic signals. It is made up of a semiconductor material with a p-type and an n-type region, and a third terminal called the base. The flow of current between the other two terminals (the collector and the emitter) is controlled by the voltage applied to the base terminal. Transistors are used in amplifiers, oscillators, and switching circuits.

MOSFET

A MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor) is a type of transistor that is used for switching and amplification of electronic signals. It is made up of a metal gate, an oxide insulating layer, and a semiconductor channel. The flow of current between the source and the drain terminals is controlled by the voltage applied to the gate terminal. MOSFETs are used in power amplifiers, voltage regulators, and switching circuits.

Diodes, transistors, and MOSFETs are essential components in basic electronics. They are used in a wide range of applications and are critical to the functioning of electronic devices. Understanding their behaviour and properties is essential for anyone interested in electronics or pursuing a career in the field.

BASIC ELECTRONICS – Part 2

There are various components that are essential for designing and building electronic circuits. In this article, we will discuss three important components – IGBT, Relays, and Integrated Circuits (IC).

IGBT

IGBT (Insulated Gate Bipolar Transistor) is a three-terminal power semiconductor device that combines the advantages of MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor) and bipolar junction transistor (BJT). It is commonly used in high-power applications such as power supplies, motor control, and renewable energy systems.

IGBTs are designed to handle high voltage and current levels, and they have low on-state resistance and switching losses. They also have a low gate drive current, which means that they can be easily driven by microcontrollers or other low-power devices.

Relays

A relay is an electromagnetic switch that is used to control the flow of current in a circuit. It consists of a coil of wire that produces a magnetic field when current flows through it. This magnetic field attracts a movable armature, which is connected to a set of contacts. When the armature is attracted, the contacts close, allowing current to flow through the circuit.

Relays are used in a wide range of applications, including automation, control systems, and power electronics. They can be used to switch high voltages and currents, and they are particularly useful in situations where a low-power control signal is used to swi