Electric Propulsion System For Electric Vehicular Technology A-Review
Electric Propulsion System For Electric Vehicular Technology A-Review
Electric Propulsion System For Electric Vehicular Technology A-Review
Lalit Kumar
n
, Shailendra Jain
Department of Electrical Engineering, Maulana Azad National Institute of Technology (MANIT), Bhopal, MP, India
a r t i c l e i n f o
Article history:
Received 12 April 2013
Received in revised form
27 August 2013
Accepted 2 September 2013
Available online 9 October 2013
Keywords:
Electric vehicular technology
Electric propulsion system
Control and management algorithms
a b s t r a c t
In recent decades, factors such as the worldwide growing concern for pollution induced climate changes,
increasingly stringent emission norms for vehicles and depleting petroleum resources coupled with
volatility in their prices have motivated and accelerated development of sustainable and clean
alternatives for transportation systems. Electrication of vehicular technology (EVT) is considered as a
promising and sustainable alternative for future transportation systems. In evolution of EVT, instability of
fuel price, fuel economy, range, performance and costs are the governing factors and prime concerns for
researchers, auto manufacturers and customers. These factors are decided by the design of the electric
propulsion system (EPS) for vehicular application and its suitable integration with various electrical and
mechanical components. In this paper, a comparative overview of EVT along with a comprehensive
analysis of EPS and a brief discussion on power ow control and management algorithms for EVT is
presented. The paper also highlights the ongoing technological advancements and future challenges in
the roadmap of EPS for the electrication of vehicular technology.
& 2013 Elsevier Ltd. All rights reserved.
Contents
1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 924
2. Classication of EVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 927
3. Electrical propulsion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 927
3.1. Energy sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 928
3.1.1. Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 928
3.1.2. Ultracapacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 930
3.1.3. Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 930
3.1.4. Fuel cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931
3.1.5. Hybrid energy system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931
3.2. Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 933
3.2.1. DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 933
3.2.2. Induction motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 933
3.2.3. Permanent magnet motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 934
3.2.4. Switched reluctance motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 934
3.3. Power electronic converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 935
3.4. Electronic controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937
4. Power management and control algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937
5. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939
1. Introduction
In conventional vehicles, petroleum products (viz. petrol, diesel)
are used to propel wheels through internal combustion engines (ICEs)
as energy conversion units [1]. However, petroleum products are
Contents lists available at ScienceDirect
journal homepage: www.elsevier.com/locate/rser
Renewable and Sustainable Energy Reviews
1364-0321/$ - see front matter & 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.rser.2013.09.014
n
Corresponding author. Tel.: 91 9752 314 242; fax: 91 755 2670 562.
E-mail addresses: lalitsahu9@gmail.com, lalit_9900@yahoo.in (L. Kumar),
sjain68@gmail.com (S. Jain).
Renewable and Sustainable Energy Reviews 29 (2014) 924940
exhaustive and it is estimated that, at the present consumption rate,
the current global petroleum resources will be used-up within the
next 50 years [2]. Use of petroleum products primarily in transporta-
tion has also raised growing concerns about environmental pollution
and subsequent climate changes. In the United States of America, for
example, conventional transportation system accounts for 3035% of
total greenhouse gases (GHG) emission, causing signicant global
warming [3]. It is projected that world population will increase from
the existing 6 billion to around 10 billion in the next 50 years while
the number of vehicles in operation is set to increase from 700 million
to 2.5 billion [4]. Given this scenario, meeting the worldwide energy
demand for the present and future transportation systems with the
least impact on the environment is an important developmental
challenge.
In order to meet this challenge, novel concepts and innovations
are being infused to make transportation systems more energy
efcient, reliable and safe with zero or reduced emissions at an
affordable cost. Majority of these innovations rely on electrication of
conventional vehicular technology and are grouped under the genre
of Electric Vehicular Technology (EVT). In EVT, ICE-based propulsion
systems are being replaced by electric propulsion system, either
partially or fully, to minimize fuel consumption and tailpipe emission.
EVT involves specialization in mechanical, electrical, chemical and
electronic aspects to achieve a reliable operation of electried
vehicles. Vehicles that employ EVT can be broadly classied as:
electric vehicles (EVs), hybrid electric vehicles (HEVs), plug-in hybrid
electric vehicles (PHEVs) and fuel cell vehicles (FCVs) [421].
In the last decade, successive development in vehicular elec-
trication brought back the electried vehicles in competition
with ICE vehicle in terms of performance and globally emerged as
sustainable alternative of conventional ICE based vehicles [13]. In
addition automobile industries are shifting towards more fuel
efcient, improved performance, higher degree of reliability, dur-
ability, safety and added comforts [23,24]. Thus, signicant efforts
Fuel Tank
Battery Power Electronic
Converter
Fuel Tank
ICE
Power Electronic
Converter
Transmission
Fuel Tank
Power Electronic
Converter
Fuel Tank
Battery Power Electronic
Converter
Transmission Transmission
Transmission
Electrical Link
Mechanical Link
Fuel Tank
Power Electronic
Converter
Transmission
Battery
Charger
Fuel
Cell
H
y
d
r
o
g
e
n
C
y
l
i
n
d
e
r
Power Electronic
Converter
Transmission
Fuel Tank
ICE
Mechanical
Transmission
Power Electronic
Converter
B
a
t
t
e
r
y
Battery
Battery
Battery
Battery
ICE
ICE ICE
ICE
Motor
Motor
M/G M/G M
M G
Motor
Hydraulic Link
G
Motor
Stack
Fig. 1. Architecture and conguration of different vehicles (a) ICE vehicle; (b) battery electric vehicle; (c) series hybrid vehicle; (d) parallel hybrid vehicle; (e) series-parallel
hybrid vehicle; (f) complex hybrid vehicle; (g) plug In hybrid vehicle; (h) fuel cell vehicle.
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 925
and resources are being spent by leading car manufacturers
and government to meet market expectations at affordable cost.
The sustainable growth and commercialization of multidisciplinary
EVT mostly rely on substantial technological advancement of EPS
and its components, especially energy source and storage system
which act as bottleneck of the technology [4,29].
EVT, essentially, has three components: (1) vehicle architecture
and conguration; (2) electric propulsion system including energy
storage system (ESS); power electronic converter (PEC), electric motor
(EM), and electronic controller (EC); and (3) power ow control and
optimization algorithm. There are plenty of review papers and
literature that deal individually with topological architecture and
conguration [418], energy source and storage systems [3159],
electrical machines [6079], power electronic converters [8096],
power ow management and control strategy [97107]. However, a
holistic, state-of-the-art review of EVT is largely missing. There is also
a lack of literature on EPS and its different components and their
suitable integration for vehicular application.
This paper presents the state-of-the-art understanding of EPS
in conjunction with all other crucial constituents of a fully/
partially electried vehicular system. The paper is intended to
offer a unied update of recent advancements in the development
of EPS in the context of EVT. In addition, the paper also highlights
current techno-economic issues and future challenges to mark
potential research issues in this area of critical global importance.
The paper is organized as follows. Section 2 describes the
classication of vehicles along with comparison amongst ICEs/EVs/
HEVs/PHEVs/FCVs. Section 3 presents a detailed overview of EPS
Table 1
Different characteristic of ICEV/EV/HEV/PHEV/FCV [8].
Characteristics Propulsion
system
Energy storage Energy source
infrastructure
Advantages Drawbacks Important issues
ICE vehicles ICE
based drives
Fuel tank Petroleum products
with refueling
station
Matured
technology
Fully
commercialized
Better
performance
Simple operation
Reliable
Durable
Less efcient
Poor fuel economy
Harmful emission
Comparatively bulky
Fuel economy
Harmful emission
Highly dependency on
petroleum products
EVs EPS
based drive
Battery
Ultra
capacitor
Flywheel
Electrical energy
with charging
facilities
Energy efcient
Zero emission
Independency
from petroleum
products.
Quite
Smooth operation
Commercialized
Limited
driving range
Higher
recharging time
Poor dynamic
response
Size and weight of battery pack
Vehicle performance
Infrastructure for charging
station
Hybrid EVs EPS and ICE
based drive
Fuel tank
Battery
Ultra
capacitor
Flywheel
Electrical power
Petroleum products
with refueling
station
Higher fuel
economy
Very low
emission
Long electric
driving range
Reliable
Commercialized
Durability
Costly
Bulky
Complex system
Complexity in
control algorithm
Increased
component count
Power management of multi-
input source
Size and weight of battery pack
and ICE
Integration of components
Plug in HEVs EPS and ICE
based drive
Fuel tank
Battery
Ultracapacitor
Flywheel
Electrical power
with charging
station
Petroleum products
with refueling
station
Lower emission
Higher fuel
efcient
Extended electric
driving range
V2G or G2V
capability
Partially
commercialized
Quite and smooth
operation
Higher complexity
Impact on grid
Higher initial cost
Sophisticated
electronic circuitry
Battery technology
Size and weight of battery pack
and ICE
Charging station infrastructure
Power ow control and
management
Impact on grid
FCVs EPS
based drive
Fuel cell stack
Battery
Ultra
capacitor
Hydrogen cylinder
or hydrogen
enriched fuel
Hydrogen rener
and refueling
station
Ultra low
emission
Highly efcient
Independency
from petroleum
products
Competent
driving range
Reliable
Durable
Under
development
High cost
Slow transient
response
Not
commercialized yet
Sophisticated
electronic
controllers
Cost of fuel cell
Cycle life and reliability
Infrastructure for Hydrogen
conditioning, storage and
relling system
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 926
and their components including signicance of EPS, status of their
components, fundamentals of the energy storage system, electric
motors, power electronic converters and electronic controllers and
related key issues. Power ow management and respective control
algorithms are discussed in Section 4 of the paper. Finally, Section
5 summarizes main conclusions of the review.
2. Classication of EVT
The vehicular technology can be classied as ICE-based and
EPS-based which are driven by EPS either fully or partially. The
signicant drawbacks of the conventional ICEV are poor efciency
to convert the fuel into useful power and excessive tailpipe
emission that has harmful impact on the environment [5,25].
To overcome these drawbacks of ICEV, EVs have been proposed.
A battery operated EV offers numerous advantages over ICE-based
vehicle such as zero emission, high efciency, independence from
petroleum products, safer, quieter and smoother operation [410].
Moreover, while the maximum efciency of an ICEV ranges
between, 30% to 35%, the EPS based vehicle can operate with a
peak efciency of around 90% [27].
The signicant disadvantages of EVs include large battery
charging time, lower exibility and limited dynamic performance.
An important limitation of battery operated EV is its limited
operating range per cycle of battery charge. This limitation acts
as a major bottleneck of the technology [4,5]. To improve these
and other disadvantages, advanced electried vehicles such as
hybrid electric vehicles, plug-in HEVs and fuel cell vehicles have
been proposed [421]. These advanced vehicles are not only
capable of competing against the conventional ICE vehicles in
terms of the performance but are also able to give higher fuel
efciency and low tailpipe emission [28].
Different types of electried vehicles have their own capabil-
ities and limitations in terms of emission rate, performance, fuel
efciency, durability, size, weight, cost, safety and comfort. Among
different types of EVs, the Hybrid Electric Vehicle (HEV) is the only
one that currently has the potential to compete with the ICE
vehicle in terms of performance, and all driving proles and offers
advantages like extended electrical range of operation, good fuel
economy, higher efciency, sufcient onboard power and better
dynamic response [510]. However, integration of automobile
technology with electrical technology adds complexity in controls,
and makes the HEV vehicle system comparatively bulky and costly.
At present, HEV technology is rated as a promising technology
which is growing rapidly and capturing signicant market space at
a fast growth rate [7,8]. Plug-in HEVs are currently at the
commercialization stage. To be commercially viable, they require
good energy policies and infrastructure for charging stations in the
near future [1317]. The efciency analysis from well-to-wheels,
the concept of vehicle-to-grid (V2G), grid-to-vehicle (G2V) and the
impact of charging station on the grid are the major issue which
are being researched for successful commercialization of plug-in
HEV [7,1619]. On the other hand, fuel cell vehicles, powered by
hydrogen, are considered as the future of EVT [2022]. The
topological architecture and conguration of different types of
IEC vehicle and EVTs are shown in Fig. 1 while the comparative
analyses and corresponding issues of ICEV and different types of
EV are summarized in Table 1.
3. Electrical propulsion system
The function of the electric propulsion system (EPS) is like the
heart of the EVT. EPS includes energy source and storage system
(ESSS), electric motor (EM), power electronic converter (PEC) and
electronic control unit (ECU) as major components. Suitable
integration of these components is necessary for the EVT to
compete against the conventional ICE based vehicle technology
[26,27]. In order to achieve the vision of sustainable EVT, EPS must
address important issues like driving prole, weight and volume of
the vehicle, reliability and exibility, compact packaging and
installation, cooling system and maintenance, these all at an
affordable costs [811]. At present, major challenge in EPS cong-
uration is to design and implement electrical machines and power
electronic converters which give better performance and which
can be easily integrated for the next generation vehicles. The
sizeable and suitable integration of different components of EPS
needs substantial research and development from component
level to system level. This integration faces many technical,
nontechnical and societal challenges including high cost of motor
material, low interest of power electronic component manufac-
turers and limited battery technology [29,30]. A synthesis of
current research and development issues, future targets for the
EPS technology is presented in Table 2. The development of viable
EVT based on advanced EPS necessitates the targeted planning and
collective efforts which will lead to increased performance, ef-
ciency and reliability, while lowering cost, weight, and volume of
Table 2
Current status and future target for EPS [30].
Characteristic R&D status Target
2010 2015 2020
Cost ($/kW) o19 o12 o8
Power density (kW/L) 41.06 41.2 41.4
Specic power (kW/kg) 42.6 413.5 4.0
Efciency (%) 90 93 95
ELECTRONIC
CONTROLLERS
C
V
T
ENERGY
STORAGE
SYSTEM
POWER
ELECTRONIC
CONVERTER
ELECTRIC
MOTOR
H/W S/W Topology Device Options CAD Technology
Fig. 2. Architectural overview of electric propulsion system [4].
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 927
the system. It will also narrow the gap between research and
development of EPS and its industrial adoption with successful
commercialization.
Fig. 2 shows a functional block diagram of EPS, including
possible types of electronic controller, control hardware, software
algorithms, energy storage systems, power converter devices/
topologies, and electrical motors and their computer aided design
methodologies. Nowadays CAD or FEM analyzed induction motors
and PM motors are favored. In the power converter technology,
PWM/IGBT inverters are the most popular along with bidirectional
dc/dc boost converter. With regard to control technology, micro-
processor or DSP-based vector control and direct torque control
technology are very common [27].
3.1. Energy sources
The strength of the electric energy source and the storage
system (ESSS) plays vital role in vehicular electrication. Basically,
ESSS includes the source (fuel cell) and onboard energy storage
device (battery, ultra-capacitor and ywheel) [31,32]. Battery and
fuel cell produce onboard electrical energy by means of electro-
chemical energy conversion but the battery stores the energy
whereas fuel cell generates the energy. Ultra capacitor, on the
other hand, relies on electrostatic principle to store the energy and
act as a source of high power density whereas ywheel stores
energy in mechanical form. The efciency, fuel economy and all-
electric range (AER) of EVT are highly dependent on the onboard
ESSS. The ESSS units must be sized such that they store sufcient
energy (kWh) and provide adequate peak power (kW) for the
vehicle to achieve the desired performance of all driving proles
[8,33].
The main factors that affect the design of ESSSs for vehicular
application include energy density, power densities, life cycle, size,
safety, maintenance, durability and recyclability at a projected cost
[3137]. The basic characteristics of specic power (W kg
1
)
versus specic energy (W h kg
1
) of fuel cell, battery, ultracapa-
citor and ywheel is shown in Fig. 3 in comparison with petroleum
fuel based ICE. It is obvious from Fig. 3, that each source of energy
has specic characteristics and dominates accordingly. Suitable
integration of these sources to form hybrid energy system (HES) is
an interesting and challenging eld for both researchers and
manufacturers.
3.1.1. Battery
The battery converts chemical energy into electrical energy and
vice-versa respectively at the time of charging and discharging.
The electrochemical battery is a combination of independent cells
which possess all the electrochemical properties. Each cell is
capable to store or deliver a signicant amount of energy indivi-
dually or in combination based on their connections [40]. High
energy density, modularity, exibility and affordability are the
factors that guide the battery technology on the roadmap of
vehicle electrication [31]. In EVT, battery stores major onboard
energy and contains high energy and power density to meet
complete driving cycles of vehicle operation.
The basic characteristics of battery for different vehicles are
different. High energy density batteries are required for EVs
whereas a high power density battery is required for HEVs and
FCVs. For PHEVs, intermediate battery technology is required so
that it can match the energy density of an EV-battery and the
power density of an HEV-battery [34]. However, batteries that
fulll the demand of PHEVs are yet to be designed specically. A
suitable battery type for EVT is the lithium based battery such as
lithium ion and lithium polymer, lead acid and nickel based
battery such as NiCd and NiMH [34]. Among these, lead acid
batteries are used for short term use because of their low energy
density. On the other hand, lithium and nickel based batteries are
preferred for medium and long term use. However, NiCd and
NiMH battery technologies are matured and their potential is
fully explored. Therefore, signicant improvement and cost reduc-
tion in these batteries in the coming years are least expected. The
inherent advantages like high energy density, low weight and low
cost of lithium based batteries invite attraction from automakers
[3138]. In Addition, the potential of lithium based batteries is still
not fully explored and maturity level is yet to be achieved.
Therefore Lithium based batteries are considered as futures
battery technology to power the electried vehicles. The dominat-
ing characteristics and comparison of different battery technolo-
gies are given in Tables 3 and 4 respectively.
Table 3
Characteristic of different battery technology [4].
Battery/parameters Lithium based Nickel based Lead acid
Ion Polymer NiMH NiCd
Nominal cell voltage 3.6 3.0 1.2 1.2 2.0
Specic energy (Wh/kg) 35 100200 60 4060 35
Energy density (Wh/l) 70 150350 220 60100 70
Specic power (W/kg) 200 4200 130 140220 200
Power density (W/l) 400 4350 475 220350 400
Self-discharge (%/mon) 48 1 30 1020 48
Cycle life 5001000 2001000 300500 300700 250500
Operating temperature (1C) 20 to 60 0 to 60 20 to 60 40 to 60 20 to 60
Rechargeable Non Rechargeable
Ultracapacitor
Flywheel
Battery
Gasoline
Fuel Cell
Limited
Operating
Range
Long Operating
Range
Specific Energy (Wh/kg)
S
p
e
c
i
f
i
c
P
o
w
e
r
(
W
/
k
g
)
Fig. 3. Specic power vs specic energy characteristic for different energy sources [8].
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 928
Table 4
Comparison of different battery technologies.
Source: C. Pilot worldwide rechargeable battery 20032007/report/pdf. [4]
Advantages ON
OVER
Lithium Based Nickel Based Lead Acid
Ion Polymer
Nickel Metal
Hydride
Ni-MH
Nickel Metal
Cadmium
Ni-CD
L
i
t
h
i
u
m
b
a
s
e
d
Ion
Polymer
N
i
c
k
e
l
b
a
s
e
d
Nickel
Metal
Hydride
NiMH
Nickel
Cadmium
NiCd
Lead Acid
Absolute
Advantages
+
+
+
+
+
+
-
-
-
-
-
-
-
-
+
+
+
+
+
+
+
+
-
-
-
-
-
-
-
-
+
+
+
+
+
+
-
-
-
-
d
-
-
-
-
d
Dielectric
Anode Cathode
Electrolyte
Separator
Porous
Electrode
Electroactive
Materials
Fig. 4. Construction and operation of (a) capacitor; (b) ultracapacitor and (c) battery.
Source: http://blog.cafefoundation.org/?p=2561:Date 18/01/2013.
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 929
3.1.2. Ultracapacitor
Ultracapacitor is an electrochemical device which works on the
electrostatic principle to store energy; therefore, it can be charged/
discharged hundreds of thousands of time without degrading the
performance [34,41]. Basically in ultracapacitor, porous carbon
electrodes, which offer high surface area (1000 m
2
g m
1
) are
impregnated with electrolyte and a small charge separation (10 )
created by the dielectric separator between the electrodes as
shown in Fig. 4(b). Appropriate modication in material selection
and fabrication brought the ultracapacitor far away from conven-
tional capacitor with very high capacitive (10005000 F) density
[42]. Ultracapacitor stores energy higher than traditional capacitor
but lower than battery and hence it can be used for applications,
reserved for battery and capacitor. It offers high power density,
long cycle life, and efcient operation. Since the rate of charge and
discharge are determined by its physical properties, an ultracapa-
citor can release energy much faster (with more power) than a
battery that relies on slow chemical reactions [4144] Table 5.
Ultracapacitors have been used for ICE based vehicles, tanks
and submarines starting due to its ability of burst power delivery.
In EVT, ultracapacitors can be used as primary energy devices for
power delivery during starting, acceleration and hill climbing, as
well as for recovery of braking energy during regenerative braking.
The combination of ultracapacitor with a battery improves the
power performance of the former with greater energy storage
capability of the latter [34]. It can downsize as well as extend the
life of a battery, reduces maintenance and replacement costs. In
the future, it is expected that ultracapacitor will become a major
dominating technology in vehicle electrication however; desired
energy density at reasonable weight and cost is a major concern.
The application of ultracapacitor in vehicle electrication is under
development and signicant improvement has to be done for
achieving maturity and commercialization in mass scale.
3.1.3. Flywheel
A ywheel that stores and delivers mechanical energy in the
form of rotational kinetic energy has been researched for many
decades but due to heavy weight and high cost, its implementa-
tion in vehicular system has been limited. Recent advancement in
frictionless magnetic bearing, carbon-ber composite materials,
manufacturing technique and sophisticated power electronic con-
trollers has accelerated the development of ywheel energy
storage system (FESS) [45]. The numerous features of advanced
FESS such as higher power density, reliability, efciency, higher
speed at reduced size and weight made it a potential candidate for
energy storage system in EVT. The ywheel rim rotates in an
evacuated containment that reduces frictional losses and ensures
safety in case of failure [4548].
A ywheel stores energy linear to its mass but square propor-
tional to velocity from supply and delivers it to the load as per the
requirement. The stored mechanical energy can be converted to
electrical energy or vice-versa by means of integral motor/gen-
erator set and power electronic converters, as shown in Fig. 5.
Flywheel gets charged by speeding up, as it accumulates mechan-
ical energy and discharges by slowing down as it supplies
mechanical energy to the EPS. The energy of regenerative braking
can be recovered by charging the ywheel, which is further used
for battery charging. Modern ywheels can store more energy and
Table 5
Comparison of ultracapacitor with conventional capacitor and battery.
Characteristics Battery Ultracapacitor Conventional
capacitor
Charging time 15 (h) 0.330 (s) 10
3
10
6
(s)
Discharging time 0.33 (h) 0.330 (s) 10
3
10
6
(s)
Energy densities(wh/
kg)
10100 110 o0.1
Power densities(w/kg) o1000 o10,000 o100,000
Cycle life
1000
2000
4500,000 4500,000
Efciency (%) 7085 8597 495
M/G
ICE-Generator Set
Battery
Power Electronic
Converter
Flywheel
Fig. 5. Flywheel placement as energy buffer in EPS design.
Table 6
Comparison of Flywheel and battery technology.
Characteristic Flywheel Lead acid battery
Technology Promising Proven
Storage mechanism Mechanical Chemical
Relative size Small Larger
Charge holding time Hours Years
Life span More than 20 years 35 years
Power and energy density High and low Low and high
H
2
O
2
Excess O
2
and other gases
Excess H
2
and Water
Fuel in Air in
Load
e
-
e
-
e
-
e
-
e
-
H
2
O
Electrolyte Anode Cathode
Fig. 6. Functional diagram of fuel cell construction and operation [55].
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 930
power than existing metal hydride or lead-acid batteries of similar
weight and volume [45,46]. Unlike the battery and the ultracapa-
citor, ywheels are independent of in-depth discharge which
improves its life cycle. The combination of the ywheel with
battery improves overall power and energy rating of the ESS
[47,48]. A comparison between ywheel and battery technology
is shown in Table 6. It spins at a very high speed therefore safety,
tensile strength of the material and location of placement of
ywheel in EVT are prime concerns and needs to be dealt with
properly.
3.1.4. Fuel cell
Recent technical advancements in fuel cell technology have
constructed the roadmap for its application in EVT as on-board
energy source. Signicant advantages of a fuel cell are eco-friendly,
simplicity, continuous power supply, durability and silent operation
along with strict conformation to emission norms of vehicular
systems [49,50]. In fact, a fuel cell combines the best features of IC
engines (they can operate as long as fuel is supplied) and batteries
(they can produce electricity directly from fuel, without combustion)
thereby reducing emissions and noise and increases the efciency. A
fuel cell is an electrochemical device that uses hydrogen (H
2
) as fuel
and oxygen (O
2
) from the air to produce electricity with water and
heat as by-products as shown in Fig. 6. To speed up the rate of these
reactions, a catalyst such as platinum is used.
In fuel cell, chemical energy of hydrogen is directly converted
into electrical power, thus eliminating the intermediate steps of
converting fossil fuel to heat and then electrical power which
enhances efciency comparatively. The specic energy of fuel cell
is as good as gasoline; however, its specic power is much less;
therefore the starting performances of fuel cell vehicles are very
poor. Consequently, to improve the power density as well as
starting performance, battery or ultracapacitor can be used in
conjunction with the fuel cell for vehicular application [5154].
Therefore it can be said that fuel cell and ultracapacitors are made
for each other to lead a perfect ESS for automotives.
There are different types of fuel cells such as alkaline fuel cell
(AFC), proton exchange membrane fuel cell (PEMFC), direct
methanol fuel cell (DMFC), phosphoric acid fuel cell (PAFC),
molten carbonate fuel cell (MCFC) and solid oxide fuel cell (SOFC)
[49,5557]. Among them, PEM fuel cell is prominent and is being
used as an energy source in fuel cell vehicles. It offers easy start at
low temperature, comparatively high power density, simple struc-
ture, small size, maintenance-free operation and ability to operate
in hostile environment [57]. Table 7 shows a comparison of
available fuel cell based on desirable characteristic for propulsion
application. The dedicated efforts are given on infrastructure for
hydrogen production, storage and relling station which are major
issues in fuel cell technology. In addition an intense research on
exploration and possibility of other fuel cell in EVT has been going
on. With technical advancement and suitable interfacing circuitry,
signicant cost reduction is expected in fuel cell based vehicles.
3.1.5. Hybrid energy system
It can be concluded that not only the power and energy
densities but also voltage and current characteristics of different
energy systems are different. Therefore, exclusive employment of
one of the aforementioned energy sources cannot meet the energy
and power demands of vehicle operation for all driving proles [8].
Compared to ultracapacitors and ywheel, a battery and a fuel cell
have much higher specic energy but much lesser specic power
as depicted in Table 8. Employment of these energy systems alone
results in higher cost, weight and volume [34,51]. However, when
these different energy systems are combined, an energy system
with high power and high energy density can be obtained. Such
kind of an energy system is termed as a hybrid energy system
Table 7
Comparison of fuel cell technology [56,57].
Characteristic PEMFC
AFC
PAFC MCFC SOFC
Electrolyte Peruoro sulfonic acid Phosphoric acid Phosphoric acid Molten carbonate Solid oxide
Design and structureSimple
Simple
Simpler Complex Complex
Temperature range 50100 1C
80100 1C
150200 1C 600700 1C 7001000 1C
Starting up time Lower
Low
Low High Higher
Stack size (kW) o1100
10100
100400
300kW-3 MW
300300 MW
12 MW
Sensitivity More
Less
Less Lesser Lesser
Efciency (%) 4060
5060
4050 4560 5065
Cell-life 210 mV/h
06 mV/h
24 mV/h 5 mV/h 08 mV/h
Advantages Low operating temperature
Quick start
Maintenance free
Fast chemical reaction
Low cost
Less maintenance
Less sensitive to impurity
Low cost
Simple structure
High efciency
Fuel exibility
Variety of catalyst
High efciency
Solid electrolyte
Suitable for CHP
Fuel exibility
Disadvantages Expensive catalyst
Fuel sensitive
Fuel sensitive
Electrolyte management
Expensive catalyst
Long start up time
Low current density
High temperature
Long Start Up time
Low current density
High temperature
Long Start Up time
Complex structure
Application Portable power
Vehicular application
DG
Military
Space
DG
Military
Electric utility
DG
Auxiliary power
Electric utility
DG
Table 8
Comparison of different energy storage systems.
Characteristics Battery Ultracapacitor Fuel cell Flywheel
Mechanism Chemical Electrostatic Chemical Mechanical
Technology Proven Promising Promising Proven
Energy density High Low Very high Low
Power density Low Very high Moderate High
Charging time Hours Seconds Minutes
Discharging time Hours Seconds Minutes
Life 35 years 410 years 10k20k h 420 years
Efciency (%) 7585 8595 4060 8090
Environmental issues Disposal Less Very less Very less
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 931
(HES), where batteries and/or fuel cell supply the energy demand
and the ultracapacitors and/or ywheel supply the power demand
[58,59]. The combination of energy system can be chosen on the
basis of vehicles design, operating proles and application.
A schematic of hybrid energy system is shown in Fig. 7 that
integrates all energy systems discussed above. The prime concerns
of hybrid energy system formation are its suitable integration, life
expectancy, maintenance, cost, durability and reliability.
Higher Torque
Higher Power
Higher
Efficency
Higher Speed
Power
Torque
Fig. 8. (a) Desired torquespeed characteristic of vehicle propulsion system, (b) Standard torquespeed characteristics of electric motors [62].
Electric Motors For EVT
Without Commutator With Commutator
Self Excited
DC Motors
Separately Excited DC
Motors
Series
Shunt
Field
Excited
PM
Excited
Induction
Motors
Synchronous
Motors
PM
Motors
SR
Motors
Wound
Rotor
Cage
Rotor
Fig. 9. Classication of electric motor for EPS.
Battery
Fuel Cell
Flywheel
Motor/
Generator
Electrical Link
Mechanical Link
Ultracapacitor
Power Converter
Direction of Power Flow
Fig. 7. Hybridization of energy source for EVT.
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 932
3.2. Electric motor
In EVT, the electric motor needs to go through frequent starts
and stops, high rate of acceleration and deceleration, such as low
speed hill climbing and high speed cruising along with different
environmental and hostile conditions. Industrial motors, on the
other hand, are usually operated at rated speed under common
circumstances [27]. Thus, the electric motors used in EVT cannot
be compared with motors being used for industrial processes. The
electric motors used for EPS should be able to satisfy some basic
characteristic for efcient operation. These characteristics are:
high torque for starting and low speed hill climbing operation;
high power density for acceleration and high speed cruising for
highway; high efciency over wide torque and speed range;
suitability for regenerative braking; over load capability during
certain period of time; controllability, high reliability and robust-
ness at affordable costs. In addition, fault tolerant capability,
minimum torque ripple, temperature management and low acous-
tic noise are other important issues for design consideration
[6065]. Suitability of electric motor in propulsion application should
be strongly approved by torque-speed characteristic illustrated in
Fig. 8(a). Moreover, the standard torque-speed characteristic of EPS is
shown in Fig. 8(b).
The choice of electric motor is the key factor in overall EPS
design. A brief classication of family of electric motor for EPS is
summarized in Fig. 9. The commonly used electric motors for EPS
include DC motor, induction motor, permanent magnet (PM)
motor and switched reluctance (SR) motor. Existing literature
indicate that squirrel cage rotor induction motors and PM motors
are best suitable options. Also, SR motors are gaining more
popularity and becoming reliable alternative for the future while
use of DC motors is declining gradually. The cross sectional view of
different electric motor is shown in Fig. 10.
The recent trends indicate that the R&D in motors is focused on
motor concepts that do not require rare earth (RE) magnets and
exploration of less expensive materials for laminations and cores
are being researched [30,68]. Development and renement of less
expensive magnets like ALNICO and Ferrite for PM motor are being
researched. In addition to that issues like design and development
of PM motors based on smaller magnets or less-expensive
magnets like ALNICO and Ferrite. In addition, development in
advanced scalable packaging designs and materials to reduce
losses, improve heat removal, and increase efciency [29].
Table 9 shows the contributing parts of the motor with respect
to cost and weight.
3.2.1. DC motor
Traditionally, a DC motor has been used prominently for EPS
due to its high starting torque and simple speed control. The
torque-speed characteristic of DC motors exhibit good compliance
for propulsion application; however, the inherent disadvantage of
bulky construction, low efciency and the presence of mechanical
commutators and brushes that aggravate maintenance require-
ments, limit its use in light, high speed and maintenance-free
vehicle application in hostile conditions [6063]. Nevertheless,
due to their simple speed control and technical maturity, DC
motors are prominent for low power EPS. Technological advance-
ments in power electronics converters and switches have helped
to replace DC machines with commutatorless motors such as
induction motors, PM motors and SR motors. The commutatorless
motors offer some tremendous advantages such as high power
density, higher efciency, more reliable and maintenance free
operation with wide speed range over the conventional DC
motors [63].
3.2.2. Induction motor
Induction motor (IM) based propulsion systems are mature and
are being extensively accepted as a dominating candidate for EPS
among various commutatorless motors. The numerous attractive
features of IM are its simplicity, high reliability, robustness, wide
speed range, low maintenance, low torque ripple/noise, low cost,
established power electronic converters and ability to operate in
hostile environment [6065]. The behavior and performance
characteristics of DC series motors can also be achieved with
induction motor by employing well matured eld oriented control
(FOC) that provides decoupling of torque control from eld control
[69]. The dynamic performance of IM can be further improved
either by applying vector control or direct torque control (DTC)
technique [71,72]. High speed operation with extended constant
power range of up to 45 times the base speed can be achieved by
ux weakening which is one of the desirable requirement for
vehicle operation [62,69]. Although, the high speed operation and
constant power range is limited by its pullout torque.
With proper choice of inverter; supply voltage and frequency
can be varied to achieve high starting torque as much as maximum
torque while keeping starting current low. Apart from the various
advantages there are several disadvantages such as high losses,
poor power factor, low efciency and low inverter usage [62,72].
Moreover, its weight and volume are greater for the same power
rating as compared to PM motors. These drawbacks of induction
motor have been acting as speed bump in the race track. These
Table 9
Cost and weight domination of motor parts [30].
Electric motor parts Cost (%) Weight (%)
Motor core/lamination 45 55
Copper 10 15
Magnets 20 5
Housing and cover 20 25
Fig. 10. Cross section view of (a) induction motor; (b) PM motor and (c) SR motor [62].
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 933
limitations have been taken into account by the researchers.
Efforts are being made to resolve these issues either at design
level or by proposing new control schemes and/or converter
topologies.
3.2.3. Permanent magnet motor
Among all the available commutatorless motors, only perma-
nent magnet brushless motors have the capability to compete
against the induction motors in vehicle propulsion system [62]. In
recent times, PM motors are widely accepted by the leading
vehicle manufacturers for designing the existing and upcoming
EPS. Generally PM motors are classied based on supply voltage
and current as brushless DC and brushless AC. To maximize the
torque density while keeping torque pulsation low, it is preferred
to operate a PM machine in BLDC mode for trapezoidal back emf
waveform and in BLAC mode for sinusoidal back EMF waveform
[74]. PM motor possesses some inherent advantages: PMs excite
the eld which offers high power density as well as reduced
weight and volume of the motor for given power rating; due to
reduced rotor losses it offers highly efcient operation; compact
packaging provides higher degree of reliability and maintenance
free operation; effective dissipation of heat into atmosphere
enables efcient cooling [6065]. Despite their numerous advan-
tages, PM motors have some limitations such as short constant
power region due to limited eld weakening capability. In addition
control and management of back emf at high speed increases size
and ratings of PECs and fault tolerant capability is an issue [63,74].
The extended speed range up to 34 times the base speed as well
as enhanced efciency of PM motors can be achieved by applying
suitable control algorithms of power converters above the base
speed [73]. Important design considerations for PM motors asso-
ciated with xed excitation for EPS include torque density, ux
weakening capability, over load capability, stator iron losses, rotor
eddy current losses and demagnetization withstanding capability.
The basic congurations of PM motors are classied based on
the location of PMs. In conventional PM motors, PMs are mounted
either on rotor surface or buried within the rotor. Surface mounted
PM motors (SPM) are a widely used design and use less magnets
whereas interior PM motors (IPM) use more magnets and offer
higher air gap ux density with higher degree of ruggedness [76].
Therefore the interior PM motors are exceedingly being preferred for
extended speed range, constant power operation over surface PM
motors. In conventional PM motors, a compromise has to be made
between low speed torque capability and high speed power cap-
ability. In order to overcome this problem the concept of hybrid PM
motor and eld excitation technique has been adopted [62,63].
Conceptually hybrid PM motor is either a combination of PM motor
and reluctance motor or inclusion of additional eld winding which
limits air gap eld. Thus the hybrid PM motors enhance the overall
operational efciency and offer wide speed, constant power opera-
tion with more complex structures. Availability, cost and supply
issues with rare-earth PMs may affect their wide applications in EPS.
3.2.4. Switched reluctance motor
SR motor is gaining more and more attention for EPS in
vehicular application. A SR motor offers tremendous potential for
vehicular application especially for HEVs and FCVs [77,78]. The
remarkable features of SR motors are: rotor without magnet and
windings offers simple and robust construction which is desirable
for very high speed as well as high temperature operation,
excellent torquespeed characteristics, fault tolerant capability,
constant power region can be extended up to 37 times, smooth
and hazard free operation [6065,77]. Limitations of SR motors
include high acoustic noise, vibrations, high torque ripple, com-
plex control mechanism and requirement of special converter
topology. Although the cost of SR motors is relatively high, their
mass production is expected to render them as cost effective as
induction motors. All the advantages are prominent for vehicular
application whereas the disadvantages are needed to be taken care
properly to have feasible SR motor based EPS.
Comparison of different motors based on desirable character-
istic for EPS is shown in Table 10. The suitability of particular
motor at particular characteristic is rated in the scale of 15. Point
5 indicates the best suitability whereas point 1 shows the poor
response. This comparison is indicative and measured in relative
based on the existing literature; however it may vary with several
factors like the design consideration of motors type, placement of
motor (In wheel or out of wheel), material used for magnet, core
and laminations, relevant power electronics converter and their
Table 10
Comparative analysis of different Electric Motors used in EPS [63].
Characteristic Motors with
commutator
Motors without commutator
Induction
motor
PM
motor
SR
motor
Controllability 5 5 4 3
Size and weight 3 4 4.5 4
Robustness 3.5 5 4 4.5
Reliability 3 5 4 4.5
Power density 3 4 5 3.5
Efciency 3 4 5 4.5
Speed range 2.5 4 5 5
Life time 3.5 5 4 4.5
Torque density 3 3.5 5 4
Technical maturity 5 4.5 4 3.5
Cost 3.5 5 3 4
Over load capability 3 4 4.5 4
Torque ripple/noise 3.5 4.5 4 3
Manufacturability 3 5 3 4
Potential for
improvement
2.5 3 4.5 5
Table 11
Electric motor used in different electried vehicles [62,63].
Make Model Market release Electric motor Power (kW)
Tesla Model s 2012 IM 215
Roadster 2008 IM 215
Hyundai Blueon 2012 PM 61
Honda Fit EV 2012 IM 49
EV Plus 1997 DC 100
Toyota Reva 4 2012 IM 50
Prius 2004 PM 30
Honda Fit EV 2012 PM 100
Civic 2013 PM 17
Ford Focus Electric 2011 IM 107
Transit Connect 2010 IM
Think City 2008 IM 34
Ranger EV 1999 IM 67
ECOstar 1992 IM 56
Renault Fluence ZOE 2011 SM 70
Tata Indica Vista EV 2011 PM 55
Fiat Peogeot ION 2011 PM 35
Panda 2009 IM 15
REVA NXR 2011 IM 13
Nissan Leaf 2010 PM 80
Altra 1997 PM 62
Mitsubishi Miev 2009 PM 47
GM EV1 1999 IM 102
Chevrolet Volt 2011 PM 111
Silverado 2010 IM 301
Mahindra Reva Reva e2o 2012 IM 20
Holden Ecommodore 2007 SR 55
Lucas Chloride SR
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 934
control algorithms etc. The main purpose of Table 10 is to bring out
the most suitable motor technology for vehicular application.
Electric motors being used by various commercialized model of
electric and hybrid electric vehicles are given in Table 11.
3.3. Power electronic converters
Power electronics is an enabling technology for efcient elec-
tric power processing which plays crucial role in shifting the
paradigm from conventional ICE vehicles to electried vehicles
[80]. The demand of electrical power in vehicular application is
growing rapidly as the mechanical components are being replaced
by the electrical and electronic components. It is expected that the
power demand in electried vehicle could reach 23 times of the
current demand [81]. In order to accomplish the growing power
demands of EPS in desired manner, integration of power electronic
components with electrical and mechanical loads of vehicle
becomes crucial. The integration of PEC not only improves the
overall performance and fuel economy but also reduces the
emission as well as the weight and size of the vehicle [8083].
For sustainable EVT, there is a need of highly reliable, exible
and fault tolerant electrical power processing system on the board
to deliver high quality of power based on vehicle demands. At
present, this responsibility have been taken care by the available
PEC that includes dc/dc converters, rectiers (dc/ac), inverters
(ac/dc) and battery charger composed of ac/dc and/or dc/dc
converters. Individually or combination of these converters can
be taken to serve the purpose; however, operation of each PEC is
entirely different from the other. Conceptually PECs perform some
of the critical tasks like ON/OFF switching of various loads; power
conditioning and voltage/current modulation to create compat-
ibility among the energy source system (ESS), traction motors and
auxiliary loads. PECs not only serve the purpose of converting
electrical power from one form to another (dc/dc, dc/ac and ac/dc,)
but also help to step up or step down the system voltage level.
In the last decade, signicant advancement in converter topol-
ogies dealing with battery charger, voltage source inverter for
motor drives and dc/dc conversion has been achieved. Regardless
of this topological advancement, still conventional PEC topologies
are being used in modern electried vehicles. Therefore, PECs for
EVT can be categorized as shown in Fig. 11. The classication of the
PECs is done based on their basic operation rather than topological
advancement.
In EPS, there are two popular congurations to interface
the ESS with inverter-motor drive as shown in Fig. 12: (a) a
high voltage ESS is directly connected to inverter-motor drive;
Power Electronic Converter
DC/DC Converter
Unidirectional
Bidirectional
Rectifier Inverter
Unidirectional
Unidirectional
Unidirectional
Unidirectional
Fig. 11. Classication of power electronic converters.
D
C
B
U
S
V
O
L
T
A
G
E
M/G
S
1
S
3
S
5
S
4
S
6
S
2
D
C
B
U
S
V
O
L
T
A
G
ES
1
S
3
S
5
S
4
S
6
S
2
Low Voltage
Energy Source
Bidirectional
DC/DC
Converter
High Voltage
Energy Source
M/G
Fig. 12. Conguration of electric propulsion system: (a) interfacing of high voltage energy source; (b) interfacing of low voltage energy source with bidirectional dc/dc
converter [82].
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 935
(b) a dc/dc converter is placed between low voltage ESS and
inverter-motor drive [82]. In the rst conguration, battery voltage
level should match with inverter-motor drive's voltage level. This
imposes certain constraints over the design and optimization of
battery, inverter and motor. In the second conguration, addition
of dc/dc converter increases overall component count but offers
several advantages over rst conguration. It boosts voltage level
of ESS to match the rated voltage of inverter-motor drive. It
provides bidirectional power ow between ESS and motor drive
which assists rapid acceleration and recovers energy to charge the
battery during deceleration and regenerative braking. It not only
offers signicant reduction in weight, size and cost of the ESS but
also give the space for inverter control and motor design [82]. The
efciency analysis of both the conguration is presented in [85].
The role of bidirectional dc/dc converter is very signicant espe-
cially in terms of better utilization of energy sources, power
management, dynamic performance, exibility, system optimiza-
tion and reduction of weight and cost [84,89].
In HESs which is essential for vehicular application, a dc/dc
converter is the key constituent which provides compatible inter-
facing and integration of energy sources. Apart from output
voltage regulation, a well designed dc/dc converter can also
control the power ow amongst different energy sources to load.
Therefore, selection and design considerations of dc/dc converters
are important factors in interfacing of energy sources. The detailed
classication of dc/dc converter topologies for vehicular applica-
tion is given in [82,89]. In addition, multiport dc/dc converter and
multiple input interleaved converters are also employed for better
energy diversication of the on board ESSS [90]. Therefore, the
basic conguration shown in Fig. 12 can be further modied in the
light of selection of dc/dc converter topology and ESS conguration.
In the advanced architecture of vehicle's electrical power
system, it is expected to have a single dc voltage bus with the
provision of different voltage level distribution and intelligent
power and load management. The modern Architecture of electric
power system for vehicular application is shown in Fig. 13. In this
architecture, different energy sources and vehicle loads having
distinct V-I characteristics and dynamic response are interfaced
with common dc bus through PECs. Since PECs are controlling,
managing and optimizing the power ow among energy sources
and vehicle loads, therefore it is considered as the heart of EPS
whereas EPS is the heart of EVT.
The basic PECs contributing weight and volume of EPS are
inverter, on-board charger, and bidirectional dc/dc converter. The
main attention is being focused on bidirectional dc/dc converter
for power ow optimization [88]. Apart from dc/dc converter,
innovative efforts are also directed towards inverters which drive
the traction motors and supply the auxiliary loads of electried
vehicle in desired manner. The selection of the inverter is based on
the topology, power rating, type of motors and the packaging
methods [80]. For PHEV, charging station demands appropriate
battery charger composed of ac/dc and dc/dc converter. This
conguration has two power stages. The rst stage shapes the
grid current for a unity power factor operation. The second stage
regulates the battery charging current [92]. By using a converter
with single-stage, advantages like simplicity in structure, higher
efciency, lesser number of components, and lower cost can be
achieved as compared to a converter with two stages; however,
battery current waveform remains unregulated [93]. The design of
battery charger for PHEVs is based on battery capacity, electric
circuitry, impact on utility grid, operator's safety, voltage level of
vehicles etc [84]. The detailed analysis, classication and compar-
ison of different battery chargers are presented in [92]. On the
basis of published literature in the eld, it can be observed that
more emphasis has been given on improvement of particular
converter type and its topology individually. Therefore, it is
expected that signicant reduction in component count, overall
weight and cost can be achieved by innovative development of
integrated dc/dc converter along with inverter and battery charger
as the sole system as proposed in [93,94].
In EPS, power semiconductor devices like insulated gate bipolar
transistors (IGBTs) and freewheeling diodes are key components,
playing a critical role in all power electronic converters. Power
semiconductor devices and their operating characteristic for PECs
are summarized in Table 12 Power devices dominate in determi-
nation of performance, cost, efciency and reliable operation of
PECs. The emerging electried vehicle market presents a tremen-
dous business opportunity for the power device manufacturer;
however certain technical hurdles to improve performance, oper-
ating temperature, reliability, packaging, and reducing manufac-
turing cost of the power semiconductor products need to be
overcome [95].The application of wide band gap (WBG) and silicon
carbide (SiC) devices in PECs leads to high-temperature capability,
high-power density, high efciency and reduces cooling system
requirement. The suitable integration and packaging reduce com-
ponent count, heat loss and improve heat transfer [29].
In addition to power electronic devices and controllers, there
are several other components like capacitors, inductors, bus bar(s),
heat sinks etc. which have signicant inuence in PEC design as
shown in Table 13. The packaging techniques should ensure proper
coordination and reliable operation of all these PEC components at
extreme vibrations and high temperatures [29]. Available PECs are
D
C
B
U
S
V
O
L
T
A
G
E
DC/AC
Converter
DC/AC
Converter
High Power
Hotel and
Ancillary loads
DC/DC
Converter
Low Power
Conventional
loads
AC/DC
Converter
DC/DC
Converter
Generator
ICE
PV
Battery
Charger
FC
UC
Battery
Fig. 13. Role of PEC in modern architecture of electrical power system for EPS.
Table 12
Power semiconductor devices for electric vehicular system [95].
Component Semiconductor devices Voltage rating (V) Current rating (A) Power rating (kW) Switching frequency (kHz)
Inverter/rectier for EPS IGBTs/diodes 6001200 100600 20100 530
DC/DC converter for EPS IGBTs/diodes 6001200 100600 20100 530
Inverter/rectier for auxiliary loads IGBTs/MOS-FET/diodes 600900 1560 24 550
DC/DC converter for low power loads MOSFET/diodes 400600 1040 12 50200
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 936
bulky and difcult to package for vehicular application, therefore,
proper integration and packaging of power electronic components
as sole system is one of the toughest and challenging tasks at
present. In order to overcome hurdles and to meet the EV/HEV/
PHEV/FCV electrical power requirement, the current research and
development is focused on some technical challenges, such as
development of new PEC (inverter, DCDC converter, rectier)
topology that reduces the part counts, size and cost of the
converters, reduction of passive element like capacitor and induc-
tors that increases reliability, reduction of EMI and current ripples
[30]. Suitable integration and packaging of these components will
give the compactness in design which will lead signicant reduc-
tion in overall weight and cost of PECs. Therefore, to meet future
requirement for sustainable development of electried vehicle
new innovations and substantial modications in power electronic
converters are necessary from component level to system. The
current trends and future status of electric motors, power electro-
nic converter and EPS based on essential characteristics of vehicle
application are summarized in Table 14.
3.4. Electronic controllers
The electronic control units are designed to provide supervisory
control of electric vehicular system. It is a combination of dedicated
system control software and electronic circuitry which includes
interfacing hardware, sensing circuitry, driver and isolator circuitry
and communication buses. Basically ECU is the integration of
sophisticated electronic circuitry, dedicated digital controllers like
microprocessors, microcontrollers, digital signal processors (DSP)
and/or eld programming gate array (FPGA); and modeling and
simulation tools with auto code generation systems like MATLAB/
Simulink, ADVISOR, PSAT, PSIM, SABER, SIMPLORER, VTB; along with
embedded software [97100].
ECU provides the exible multi-input/output channels for
communication among various components of the vehicular
system. The controller synchronizes or coordinates with the
components of EPS such as ESSS, PEC, electric motors along with
ICE, transmission system, pilot commands and operating modes of
the vehicle [101]. The ECU controls and maps the status of electric
motor, ICE and vehicle behavior based on a selection of system
inputs. Standard pilot commands, such as braking and acceleration
are supplied as system input to the ECU from appropriate sensors
and CAN buses. Based on system input and CAN bus information,
certain mapping of different system components are performed to
monitor their current status to select the vehicles mode of
operation [100]. The entire information is processed in digital
controllers through programming, which performs the required
calculation and converted into desired power and/or torque and/or
speed commands for each wheel individually or simultaneously
[97]. The output of ECU which is driving signals for various
components of the vehicle is communicated through CAN trans-
mitter over different sections of vehicles. The ECU is not only able
to implement a variety of advanced vehicle control and dynamics
algorithms but it also monitors overall vehicle behaviors and
observes the performance. The ECU is placed near to motor drives
and engine, therefore it should be designed such that it can bear
temperature ranging from 801400 1C and extreme vibrations
which are major challenge. A self explanatory architecture of the
ECU is shown in Fig. 14.
4. Power management and control algorithm
In EVT, the control and management of power ow from multiple
energy sources to power electronic converters and fromconverters to
different vehicle loads, is a major challenge. The technological
advancement transforms the early ON/OFF control system to modern
adaptive predictive control era that improves the overall perfor-
mance of control system [102,103]. Dedicated efforts are being given
for the development of appropriate control and energy management
strategy which is very essential, specically in HEV operation.
A control strategy is dened as an algorithm, which is a set of
instructions or laws regulating the overall operation and power owof
the vehicular system. The algorithm can be considered as a black box
that performs desired calculation on the basis of given information.
Input information mainly contains measured data of vehicles operating
condition such as acceleration, braking, torque demand, trafc infor-
mation and driving prole. The outputs of the algorithms are decisions
that command driver circuits to turn ON or OFF the vehicle's
components or to modify their operating region towards optimization
[102]. A properly developed control algorithm and management
strategy should satisfy certain objectives such as vehicle power
demand, monitoring of battery's state of charge, fuel economy, reduced
emission, efciency optimization and smooth coordination between
electrical and mechanical components. Therefore it becomes prime
concern to adopt systematic process for power ow control and
optimization, while designing the controllers and control algorithms.
Controllers are mainly classied into two groups based on their
mathematical modeling strategy; (1) rule based systems and
(2) optimization based systems [101107]. The detailed classica-
tion of both the controllers is given in Fig. 15. Basically, rule based
controllers are designed to obtain maximum fuel economy, ef-
ciency and reduced emission for predened driving proles. Rule
based controllers are tuned based on sets of rules or criteria
written on the basis of vehicle information. In this controller state
diagram and ow charts are commonly used for performance
Table 13
Cost and weight contributions of PEC components [30].
Power converters components Cost (%) Weight (%)
Power switch/heat sink 33 33
Capacitor/inductor 20 22
Bus bars/connectors 13 15
Sensors 7 5
Housing and others 27 25
Table 14
Present and future status of EM, PEC and EPS [29].
Characteristic
Electric motor Power electronic converter Electric propulsion system
2010 2013 2015 2020 2010 2013 2015 2020 2010 2013 2015 2020
Power density (kW/L) 3.7 4.8 5 5.7 8.7 10.2 12 13.4 1.06 1.15 1.2 1.4
Specic power (kW/kg) 1.2 1.3 1.3 1.6 10.8 11.5 12 14.1 2.6 3.1 3.5 4.0
Efciency (%) 90 91 92 93 91 92 94 97 90 91 93 95
Cost ($/kW) 11.1 9.5 7 4.7 7.9 6.5 5 3.3 19 16 12 8
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 937
optimization of each component individually rather than cumula-
tive. On the other hand optimization based controllers are
designed to develop optimal control strategy for propulsion
system by reducing the cost function. The cost function is derived
based on the past and future information of driving prole,
component parameters and expected performance of the vehicles.
This controller is tuned for overall vehicular system optimization
rather than component level [105]. Both the controllers have their
own pros and cons which are summarized in Table 15, and need to
CAN BUS
HOST COMPUTER
CAN Reciever
System Input
CAN Transmitter
Driving
Signals
ELECTRONIC CONTROL UNIT (ECU)
C
V
T PEC ESSS
ICE
Generator
Motor
Charger
ELECTRIC PROPULSION SYSTEM (EPS)
ICE MAP Accelerator MAP Brake MAP
Operating Mode: Electric/Hybrid/ICE/Charging
Vehicle System
Controller
ESSS
Controller
PEC
Controllers
Fig. 14. Architecture of electronic controller for EV/HEV/PHEV/FCV.
Source: www.proteanelectric.com /Date: 09/03/2013.
Control and Management System
Rule Based
Deterministic
Rule Based
State Machine
Power Follower
Modified Power
Follower
Thermostat Control
Fuzzy
Rule based
Conventional
Adaptive
Predictive
Optimization Based
Casual/Real-Time
Optimization
EFC Minimization
Robust Control
Model Predictive
Decoupling Control
Acasual/Global
Optimization
Linear Programming
Dynamic Programming
Stochastic DP
Game Theory
Genetic Algorithm
Control Theory
Fig. 15. Classication of control algorithms and power management techniques for EVT [104].
Table 15
Comparison between rule based and optimization based controllers.
Rule based Optimization based
Implementation Simple Complex
Speed Fast Slow
Sensitivity Low High
Optimality Approximate Exact
Information needed Less More
L. Kumar, S. Jain / Renewable and Sustainable Energy Reviews 29 (2014) 924940 938
be addressed properly before implementing the algorithms. The
global control strategy with real time optimization has been the
best proposed solution for HEV/PHEV so far [103].
5. Conclusion
In this paper, topological conguration of different vehicles has
been reviewed with emphasis on electric propulsion system and its
components. Contemporary and futuristic global scenario of envir-
onmental, political, economical and technological factors has accel-
erated the interest towards partial and/or complete electrication of
vehicular technology. A comparative analysis of EVT shows that the
different electried vehicles are at different stages of evolution and
commercialization. EVs/HEVs are gradually commercializing and
capturing a signicant market space. PHEV's are ready to be
commercialized. Suitable energy policy and infrastructures for char-
ging station will accelerate the commercialization of plug in HEVs
very soon in near future and it will sustain for a long time. FCV's are
under development and are yet to be commercialized. Fuel cell
vehicle can be seen as the future of transportation system with
suitable technological advancement. Despite these developments,
the members of EVT face different technical and nontechnical
challenges and require certain targeted strategies and planning for
their commercialization.
The sustainable development of EVT heavily depends on
electric propulsion system and its components. The comprehen-
sive review of EPS indicates that the recent modication in EPS
due to technological advancement of its members like ESS, power
electronic converter, electric motor and electronic controllers,
makes EVT capable to compete against conventional ICE based
vehicular technology. For successive advancement of EPS, techni-
cal breakthroughs are necessary from device level to system level,
so that improved performance, higher efciency and reliability can
be achieved. The suitable integration and packaging of these
components is a challenging task that needs to be addressed
properly so that signicant reduction in weight, volume and cost
can be expected with better cooling system and reliable operation.
The successful penetration of EVT will mainly depend on the
substantial technological advancement of EPS and its components
that in turn decide dynamic performance, fuel economy, durability
and cost of the vehicle.
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