This content details the practical aspects of electric vehicle (EV) components and control systems, focusing on motor operation under varying loads, fault scenarios, and the underlying control methodologies like Field-Oriented Control (FOC). It also covers Battery Management Systems (BMS) and showcases real-world EV components.
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Hello. Okay.
next. Okay, let's start with main MCB
and ignition switch and uh ignition key
Let's it be an normal
and then we can turn on our DC supply
for the batteries.
Let's check how the load increase when
the increase our load for the motor how
the speed will varies and how the
current will be varies with respect to
the load.
Uh in this kit we have a one component
which is helps to increase our load.
This is the thing which is helpful us to
increase the load of load like it is a
zero load then we can convert into 50%
of the load and again we can convert it
to 100% load on the motor specifically then
let's we'll do in zero let's see how the
voltage will be increases and the
This one is without any load. We are
applying the acceleration like it is a
resistive load applied on the motor. we
can uh like it is a mechanical load
which is applying on the specifically
motor. After that see we are applying
50% of the load to the specifically
motor. Then we check the what is the
current? What is the current and what is
the voltage and the speed?
>> So what should be the current? The
current should increase or decrease what
to 61 kilome per the speed of the motor
and the current is the DC wage is uh 73 23.97
23.97
and this is the parameter is 4.4
Then the current is very increasing.
Okay, then let's have a 100% load on the vehicle.
vehicle. Okay.
Okay.
Then we can check how the suddenly the
increasing of the current and the speed
increase in this current. See it is
going about 9 10 11 12 in.
in.
When the load increases then current
And frequency will be remain only likely
likely
but you can see the variation in
current. Okay. So current is drawing
maximum. So it is taking around 18
something here to 18. A okay. So more
than 18 amps of current is drawn by the
>> Okay. If you have any doubts, you can
ask in the comment section about the
Okay, nothing is there. I think no one
is asking any questions. Okay, let's go
for a new which can be occurs in any
time for the EVs like our IC engines
like any fault can be occurs like an
ignition failure or emergency braking
occurs for the electric vehicle suddenly
any brake failure this type and the
fault and then the space supply be
reduces in that time what will happens
in EPS let's see here we have a three
things has as I shown in the morning we
can see one is the ignition failure and
another emergency braking fail and one
is the phase interruption like we can
see when
everything is on condition if you if any
ignition failure will be occurs like a
ignition it is in the failure when we
press it the it is occurs a failure
option then we can increase if we see if
we increase the
press acceleration also it will be not
in the on conditions. Okay, it will be
not in the working because there will be
no supply in between the acceleration
pedal and the main supply. It will be it
will be cut down. Okay.
I think I am going speed or any issue.
No replies are coming
Okay.
Next. Emergency stop button.
Emergency. Please explain. Little slow. Okay.
Okay.
Ignition. Ignition. Now
Ignition Ignition
in the battery input in the motor
Accelerate. Accelerate.
Emergency stop.
VCU, ECU and MCU motor control between
these things they used for communication purpose.
We required this much of supply for a
specific acceleration. acceleration. Okay.
V this use and anything like as a RN
like as a lights most of the communication
communication
It is a two wire which is a twisted
which is used for communication in
between the components like as ECUs,
So as we are discussing like um related
to this. So in the morning as we have
Can you guys see this properly? Is it
Okay, good. So the thing is like um from
the three-phase so whatever the
three-phase inverter you will have that
from there like you you are taking
three-phase current. So I IW are the
three-phase currents.
You get a pen and that is
>> No, but I can't show like No, but I
can't show like you just give me pen and
book. That is enough book.
book. Yeah.
Okay. So from the can and can can they
can see like you just check in comment
also. Okay. So from a three-phase inverter
inverter
because from this before it will be an
DC voltage. Okay. So from DC voltmeter
you will be getting three-phase
three-phase inverter from that the it is
okay so the whatever the current you
will be getting you will be transferring
it to the motor it might be any motor it
might be BLC or PMSM okay so from this
you will be taking three-phase currents
okay so How many of you have heard about
this clark and park transformation?
Just say comment yes or no. Okay,
we'll discuss park and cl transformation
because uh in FOC control method FOC
control method is a method like where it
is used in motor controller. Okay. To
control the motor you will use FOC
controller. Okay. So from here we are
getting I A, IC like three-phase
currents you are transferring it to you
are giving it to the Clark
transformation. Okay, Clark transformation.
So that you are converting it into so A,
B and C.
>> Okay. No no I
Nice.
One more. Am
I audible? Okay.
Now perfect very good okay so from
three-phase inverter we are taking three
three currents okay so here they are
considering IU IV and IW okay so
threephase currents they're taking so
three parameters they are using CL
transformation they're converting using
a mathematical model okay so from
mathematical model they're taking them
into alpha and beta angles so from
three-phase current it is converted into
a two-phase two two-phase current like
two two parameters that is I alpha and
is this clear
okay good so from alpha and beta using
part transformation we are taking it
into d and q so d and q is nothing but
direct axis and quadriure axis
So so many of you know about like what
is direct axis and quadricure axis
because you might have gone through this
in earlier classes. So direct axis and
quadr access are the uh quantities like
where direct access current and quadial
access current are considered in the
motor you will get to know like direct
access and quad access. Okay. So from
this uh they are transferring it to a pi
controller where you are comparing and
making the ID as zero because we want
two independent quantities where you are
making the ID to zero to get the maximum
efficiency out of it like the losses
will be less reason being D is can you
explain uh I'm explaining only right
okay so ID they are making it into zero
using a PI controller and they're only
passing the IQ value here and again that
IQ value they're converting it into
alpha and beta that is U alpha sorry V
alpha and V beta using PWM generator
again they are passing that to the
inverter so that current what you have
received is transferred into the motor
Okay. Great. Just go through the FOC
control method because it's a important.
Okay. Someone said no also. Sanjzan.
Okay. Sanjana. Okay. Let me explain one
more time. Listen carefully. So from three-phase
three-phase
inverter you are taking three currents.
IU, IV and
IW. Okay. So these three parameters you
are considering the current you are
taking some separate faces that you are
converting into alpha and beta using
cloud transformation. So cl in cloud
transformation is a mathematical model
where you are converting a three-phase
parameter into a two-phase parameter. I
hope this point is clear for everyone.
Okay. From I alpha and I beta using part
transformation you are converting that
into a independent quantity where D and
Q are taken direct axis and quadr axis
little bit down now
I can see clearly I can see yes
okay good so you have taken taken them
into independent quantity P and Q where
using PI controller you are making the
ID as zero. Reason being direct access
when it becomes zero so the rotational
parts are like made into zero. The only
the torque parameters are considered. So
using PI controller you're converting D
into like D is becoming zero and only Q
values are taken. So from Q values you
you are using inverse uh park
transformation and converting them into
alpha and beta. So here clark
transformation then park transformation
then again from after this pi controller
thing the inverse clark is going to
from this you'll get three-phase
voltages VAB and VC
that you are going to give it to the BLC motor.
motor.
You guys have any doubt apart from this?
I hope the doubt is clear but still if
Okay, good. So we'll we'll go into the
next setup. We have a BMS setup. What
you want to show like? Okay, we we'll
complete BMS setup and we'll come back.
Okay, we'll show a BMS setup. Okay, so
we'll continue. Uh give us two seconds.
Hi guys like this is one of the setup
that we have like kept it for the
afternoon session. This is a BMS
technology training kit. Okay. So as you
can see so we have connected the cells
over here. So I'll get the text also.
So we have connected the cells here.
Okay. So these cells we have arranged in
series. So how many cells are here? Can
you see? 1 2 3 4 5 6 7 8 Total eight
cells are here. You guys can have a
I'll show you the which cells we have. Okay.
the cell from there it's fine can get
so these cells are actually um
So it's a lithium cell only. Okay. I I
hope the you can see also lithium ion cell.
>> Yes.
>> Okay. Good. So we have here one more
tester internal resistance tester. Okay.
we can check here internal resistance
how the internal resistance of the
so what is the resistance of the cell
It's a low battery. Okay fine. No
problem. So how much is the nominal
voltage of the uh lithium ion cell? How
much is it? Can you guys say it in
comment section?
How much is the nominal voltage of
Okay. Sushita told it correctly. It is 3.2.
3.2.
Okay. So nominal voltage you you guys
are telling 3.7 like it's a full charge
voltage not the nominal voltage. Okay.
In lithium cell the voltage will be of
3.2. Okay. So the total if you calculate
how much it should show show to you uh
in the setup like we have connected
eight cells in series. So can you guys
calculate how much will it show will it show?
show?
So as it is showing in DC voltmeter
because I have connected like from the
first cell to the last cell like we have
connected them in series. So it is
showing it as 25.2
25.2 volt.
volt. Okay
Okay
multimeter you can calculate and comment
Also see by using the eight cells only
we running this motor which is called as
a PMDC motor which is permanent man supplied
Okay. So I am connecting like how much
is the cell individual cell voltage? Okay.
Okay.
So we'll connect one by one.
So we are connecting for the first cell.
So I want the first cell voltage. So how
much is it showing? 3.7. Wow. Nice.
Someone told 3.7 at that time. I told
like but the cell is full charge. Okay.
So it is showing >> 3.7.
>> 3.7.
>> 3.7. It's not like you guys were right.
Okay. Good. So I I I am connecting it to
the second cell. Then it is showing 6.6
6.6. 7 also. Okay. So when I connect it
to the third one, so the voltage is
getting increased. So 9.7.
So next we'll connect it into the fourth cell.
cell.
Okay. The voltage got increased. It's
13.5 now. Okay. So we'll connect next to
the fifth one.
Sixth cell we are going to connect.
Okay. So how much is it now? 19.1.
7th cell.
Once we are connecting to the last cell
the total voltage here is
25.4 4 which is almost equal to 25.3
which is showing in the DC meter. So we
have a smart BMS technology also like
like if we connect like the total cell
wtage. So the total it will be 81 or
something because 16 cents. So when we
connect it like we'll get around
uh like for full charge thing like we'll
No, the thing is like it won't get
affected but every time we can't like
fully charge like today we are going to
explain you guys like I wanted you you
guys to be in fully charged so we have
charged our battery also okay so that is
the only reason it's not like we have to do
Guys, we'll show one more thing to you.
Uh I'll I'll I'll just uh carry on with
that. So, Guru uh you just connect from
your phone.
We'll show how the battery is connected
also like uh active uh balancer will
>> See guys, this is actually the active
cell connector. This is from smart
active balancer. Okay. So smart active
balancer. So they have uh given a
connection over here. So we can connect
it to a battery pack. So we can see the
voltage and current values.
So now we have connected this battery
Can't talk.
So the pressure has been already shown.
>> Okay. So this is one of the setup like
where the cell can be like sell separate
individual cell voltage you can
calculate. Okay. So this is one of the
setup I just wanted to show. So next
Guras sir will show you like some
components like which are used in real
time. Reason being you guys are
attending in online. So he wants to show
like how it looks. So we we'll show few
It is like a just connecting like
temperature full voltage value and
difference between the cell voltages. We
we'll share the pick in group. Okay,
we'll we'll share it with you guys.
Indicating lights indicating colors. Okay.
Most of the time you have not seen like
motor control unit, the VCUs and other
types of BMS which are used in the noway
in Ola. Are you interested to see those components?
about Ola cell battery pack.
How is the connections in used in uh okay
okay
Okay.
So, have you guys seen this battery pack?
One second.
>> So,
>> I can explain them.
>> Okay. Present is opening something. See
this is the one of the type where the wa
inside connections are made as per you
have seen the cylindrical cells
lithiumion cells and these are the types
of connections for like they having the
positive and negative
>> let's see sir will show you something
special I think
>> not something special so this is the Ola
battery pack. Okay. So, this Ola battery pack
>> now.
>> Okay. So, this is the Ola battery pack.
You can see here.
Can you see Ola S1 Pro? Okay. So, this
is the battery pack. If we remove this
connection, so inside it will look like
this. Okay. The whole battery pack what
you can see right now over here. So the
cells are they are connected
interconnected in this manner with a
So this this we are connected. Okay. So
like how much is the voltage? Can anyone guess?
guess?
Because like we have two like two
layers. So these two are connected. Once
you connect these two, so it will make a
battery pack like this.
So I just wanted to give this US for a reference.
Okay. Then uh motor motor control unit
like this is the one of the type which
is used in you can see here is the one
of the type which is connected to the m
what we call as a PMSM motor. It is the
PMS motor. We having the three PH which
is yellow, blue and green color. And
here we are having the input two inputs
which is is which is come from the
battery supply. And another one is a can communication
communication
link. It is a one of the communication
where we use it for the communicate
between the total and the motor. Okay.
Okay.
This is the one of the newest design for
the wall to motor controller. In this
Okay. I will show another one which is
Now you can see I think it is better
Okay. This is visible. No, I think it is
This is the one of the motor control
unit which is used in Ola.
Yes, you can visible. See having the
three terminals which is flows to the
motor. One R Y. These are the three
terminals and these are the two supply
which is a red one and it is a black
one. And another one is a CAN
communication which is helpful for the
communication between the total battery
and the motor. Okay.
Now also it is not visible. I think uh
it is like as we are using PMS. It is
one of the controller. It is built for
the FOC. I think FOC is the one of the
technology which is used here and also
Okay. Then you can also see another type
of motor which motor controller which is
This is the one of the same type but it
is old one compared to this. It is the
Okay. And we also see DCDC converter
which this is the DCDC converter which
convert the 36 W and 72 volt to output
of 12 volt and 0 point which what is
happening here? We are converting 36 volts
volts
and 72 volt to 12. What is happening?
Which converter is used here? Anyone can comment.
Hello. Which type of conversion is
happening in this DCDC converter which
is used to convert 36 or uh 72 volts to 12?
12?
Yes. Which type of conversion? Buck
conversion. Boost conversion with buck boost.
boost.
Okay. It is a buck converter. Good. It
is good. and other like I see this is
the one of the chargers we are using in
the home application in home only for EV charging
charging
seen morning I think again I'm showing
this the one of the charging type which
is used for the EVs in the home it take
more time compared to the outside chares
it will take more time to convert the AC
supply into DC supply you can see and so
I'll show you the values
I hope the session was good. Uh
so this is what we wanted to show you guys.
guys.
And uh one more thing we have like in a
vehicle how they are connected. Okay. So
So this is actually like BN BNM
BNM uh 1200 like EV vehicle only. So in
this vehicle they're using actually
using two battery pack. One battery pack
will be placed over here and another one
battery pack will be placed in the
front. Okay. So like two like the uh uh
>> BNC challenger actually so two battery
packs they can use like they they are of
swappable technology. Okay. So what
Gurash sir shown you just now the motor
controller looks like this. It's
actually mounted over here. So it's
clear only. So like we are giving
three-phase uh which which is
transferred into the motor. So you can
So the motor which we have used over
here is a hub motor. So it is connected
to the wheel.
So actually some network issue is there
I guess. So that is the reason like you
guys couldn't see.
This is hub motor like which they have
connected. So we are if we connect a
battery pack of more than 60 uh which is
around 60 volt we can run this vehicle.
So this is a readym made vehicle like
which we have like assembled when we
when we came in VTU Bagawi. Okay. So
this is one of the vehicle and as you
guys know this is Ather 450. Okay.
Okay.
Hope the session was useful. If you guys
have any questions like uh we'll be here
for five more minutes. You can ask your doubts.
Hope you guys enjoyed the session. Okay.
Thank you. If you have any queries, you
can write it down. So,
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