Graduation Design (Dissertation) of Wuhan University of Technology

The Whole Layout Design of Electric Logistics Car Type TZYP5031XXPY

School: School of International Education

Specialty amp; Class:Automotive Engineering GJ1302

Student name: Wang Yiqun 王轶群

Tutor: Zhong Shaohua 钟绍华

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ABSTRACT

Nowadays, Electric Vehicles have a significant role in reducing emissions and dependence on fossil fuels. And introducing Electrical vehicles to logistics car is a widely discussed topic. However, the design of domestic electric logistics vehicle is relatively falling behind the world, which means while western car industries have already deployed the next-generation electrical logistics car design (the whole battery system is design into the chassis), the electric logistics-cars design in China is still modified from the gasoline engine structure and the battery is attached on the chassis and vehicle body. This paper introduces the design principles of the layout of the whole electric logistics cars.

Key words: Electric vehicles; logistics vehicles; battery; motor.

Content

1.Introduction 1

1.1 Current development status of Electric Vehicle and Electrical Logistics Car 1

1.1.1 The necessary of electrical trending on vehicle 1

1.1.2 The key technologies of electric vehicle 1

1.1.3 Current development status for Electric Vehicle 3

1.2 Brief introduction about Catia 4

2. Basic car details of Electrical Logistics Car Type TZYP5031XXPY 6

3. Battery system design 7

3.1 The demand of battery for an EV 7

3.2 Lithium-ion Battery 7

3.2.1 The operating principle of lithium-ion battery 8

3.2.2 The structure of lithium-ion batteries 9

3.2.3 The characteristics of lithium battery 9

3.3 Lithium polymer batteries 10

3.3.1 The structure of Lithium polymer battery 10

3.3.2 The characteristics of lithium polymer battery 11

3.4 Two current shortage of the Ternary Material lithium battery 11

3.4.1 Quick charging and impendence 11

3.4.2 Study of thermal runaway 11

3.5 Battery management system (BMS in short) 12

3.5.1 Thermal management system 13

3.5.2 Battery package control system 15

3.6 Battery Choice for TZYP5031XXPY 16

4. Motor system design 18

4.1 Permanent magnet brushless motor (PMBLM in short) 18

4.1.1The advantages of PMBLM: 18

4.1.2 Disadvantages: 18

4.2 The structure design of PMBLM 19

4.2.1 Permanent magnet motor 19

4.2.2 Rotor location sensors 20

4.2.3 Electronic commutation circuit 20

4.3 Electrical Motor Choice for TZYP5031XXPY 21

5．Conclusion 22

Reference 23

Acknowledgement 24

1. Introduction

1.1 Current development status of Electric Vehicle and Electrical Logistics Car

1.1.1 The necessary of electrical trending on vehicle

The transporting powering systems are always in the core position of technology revolution and economy transition. In 19th centuries, the coal and vapor train launched the European Industrial Revolution, which initiated the Industrial Era. Then in 20th centuries the usage of internal combustion engine thrived The U.S. and bring human being into oil economy. In the meantime oil challenged environment. Into 21st centuries the shortage of oil-related energy and the severe pollution became the two main challenges of automotive industry^[1]. The traditional injection engine is destroying eco systems more severally as the number of cars throughout the world is still significantly accumulating. Due to the pressure of energy and environment, the New Energy Vehicles (NEVs) technologies gained a dramatically development, and the competition of different kinds of technologies suggest that human being is transiting to the “Post Oil Era”^[2]. It also means a golden developing period of automotive powering technology. For now, it is commonly believed that the hybrid vehicle, the pure electric vehicle and the fuel cell vehicle become the three main representatives of the future automotive powering system transition. Specially, the massive enhancement of core technology, such as energy density of battery, life and security of battery, etc. made the plug-in hybrid electric vehicle and the pure electric vehicle become the mainstream developing direction of New Energy Vehicle.

1.1.2 The key technologies of electric vehicle

The key factors include the body structure technology, the battery technology, driving motor technology, the whole-car control strategy and the charging technology.

1.1.2.1 Body structure technology

The electric car is a comprehensive high-tech product. Apart from battery and motor, the vehicle body structure also contains lots of new technology. For example, applying the light materials such as magnesium and aluminum alloy and the structural optimization could decrease the mass of car by 30~50%. And the aerodynamic optimization could reduce the air draft by 50%. On the other hand, the way for energy recycle when braking, descent and idling is still under study.

1.1.2.2 Battery technology

The key restricting factor for EV development is the battery volume, which is still not ideal enough. The main evaluation factors for batteries are energy density and power density^[5]. The poor performance of these factors lead to the insufficient mileage and long charging time. But with recent developments, the battery performance has reached a satisfying standard and could fit the practical demands.

1.1.2.3 Motor and its control strategy

a. Motor performance analysis

The current motors for EVs and their characteristics are listed below: DC Motor (DCM), Induction Motor (IM), Permanent Magnetic Brushless Motor (PMBLM) and Switch Resistant Motor (SRM).

Table 1.1