International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN (P): 2249-6890; ISSN (E): 2249-8001
Vol. 8, Issue 1, Feb 2018, 1255-1270
© TJPRC Pvt. Ltd.

DESIGN, ANALYSIS AND FABRICATION OF SOLAR PV POWERED

BLDC HUB MOTOR DRIVEN ELECTRIC CAR

M. PREMKUMAR1, JSV. SIVAKUMAR2, R. VIJAYA KRISHNA3 & R. SOWMYA4

1, 2, 3
Assistant Professor, Department of EEE, GMR Institute of Technology, Rajam, Andhra Pradesh, India
4
Research Scholar, Department of EEE, National Institute of Technology, Tiruchirapalli, Tamil Nadu, India
ABSTRACT

Road transport has been dominated by petrol and diesel engines historically. Due to the environmental impacts and
limited resources, both alternatives are unsustainable. The renewable energy directive, particularly identified as technology
innovation, energy efficiency and renewable energy sources in the transport sector and it is considered as one of the most
effective tools in reaching the targets in terms of sustainability and security of the supply. In this context, it is obvious that
reaching the challenges depend on the rollout of Electric Vehicles (EV) as a sustainable transport and higher penetration of
renewable energy sources. Here, a commercially marketable and simply designed electrical solar vehicle can replace fuel
vehicles, controlling pollution and promoting wellness of the environment. It also creates awareness about the solar panel’s

Original Article
future possibility and feasibility. Each part of the vehicle is designed and analyzed. This paper covers broad view on design and
fabrication of a commercial renewable energy solar vehicle considering all the parameters within the limitations.

KEYWORDS: Renewable Energy, Electric Vehicle, Solar PV, Sustainability, Zero-Emission & Solar Race

Received: Dec 30, 2017; Accepted: Jan 20, 2018; Published: Feb 13, 2018; Paper Id.: IJMPERDFEB2018146

1. INTRODUCTION

Today’s transportation sector accounts for 23% of CO2 emissions, 72% of which is being emitted by road
transport. The CO2 emission regulation for new cars has come as a response to set emission performance limits for new
passenger cars with the goal of establishing a road map change for automotive sector. One significant challenge will
consist in accommodating cost efficient fashion through active involvement of customer and better flexibility of the
demand [1].

Many researchers are jointly working on future energy challenges, both in terms of security and sustainability,
in that achieving a sustainable transportation system will be the critical component. Electrification of the transportation
system seems to be the most promising alternatives in terms of increasing the security of supply and promoting a
sustainable transportation through less pollutant resulting from conventional transportation [2], [4].

However, the care should be taken to the primary energy source, in fact the emissions generated by
petrol/diesel engines could be counterbalanced by emissions generated from power plants. Further, centralized power
source will result in high transmission losses and less efficiency. EV deployment may be considered as sustainable
emission only when powered by the considerable amount of Renewable Energy Sources (RES). From power supply
point of view, there is a limitation of accommodating an increasing level of RES sources under load demand from EV
users both at peak and off peak time. On the other hand, an efficient penetration of RES depends on the ability to inject
the maximum power within the stability of the electricity networks. Many studies had acknowledged and investigated

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1256 M. Premkumar, JSV. Sivakumar, R. Vijaya Krishna & R. Sowmya

the EV potential in demand side management enhancement [6].

A zero-emission vehicle is powered by Solar energy by means of solar PV panels through storage batteries, and
the traction is obtained by an electric motor. But, solar energy for EV is not an issue, because several critical points also
need to be analyzed [7]. For example, the efficiency and costs of solar PV panels, how to maximize the solar irradiation,
and the control and energy management. Nowadays, there are many researchers developing solar vehicle around the world
for various purposes. From the research point of view, interesting contributions have been presented by researchers in two
years like solar PV powered, zero-emission electric vehicle and solar/wind powered hybrid EV, with an internal
combustion engine was proposed. A hybrid system for an EV is proposed, including solar PV, storage battery and super-
capacitor, with the system configuration and different control strategy. The vehicle involving battery powered and charged
by PV panels is used for agricultural activities in remote hilly areas, with the aim to produce the cleaner power hence the
usage of diesel is reduced in agriculture. Other hand, many solar vehicles are built to participate in different solar vehicle
championship around the world to test and examine the new technological advancements and its potential to design the
zero-emission vehicles [3]. The design and development of electric solar vehicle is an initiative for students and
researchers of various domains, motivated by solar vehicles race called “Electric Solar Vehicle Championship” in India.

The solar vehicle is another step to save the non-renewable sources of energy. The solar powered electric vehicle
is also considered, because of less noise, less pollution and reduces greenhouse gas emission (GHG) emission. EV consists
of PV panel, charger controller, battery, electronic speed controller and BLDC motor. The objective of the proposed design
is, the energy drawn from the solar panel should be used to charge a battery which runs the motor of the vehicle. A simple
DC-DC converter acts as interface between the solar panel and the battery to obtain the required constant voltage and it
will extract maximum power from solar PV panel. Because of low maintenance, low weight, high efficiency, long life and
compact design, BLDC motor is preferred over PMDC motor. This paper focuses on the design of solar PV, selection of
battery and basic boost converter, mechanical structure and braking system for the solar vehicle driven by BLDC motor.
The prototype solar vehicle is built and the vehicle is tested and verified. The rest of the paper is organized as follows:
Section 2 focuses on the mechanical design of the vehicle. Section 3 deals with the electrical design of the vehicle. Section
4 discusses the experimental results. Finally, conclusions and future work are presented in Section 5.

2. Design and Testing of Mechanical Structure

2.1 Chassis Frame Structure

The frame of a vehicle is the skeleton. Safety for the driver and costly components such as panel and motor should
be ensured from damage. The other main factor is weight reduction, which is a challenge to improve safety and stability
with reduced weight. By considering the above factor, the frame is made up of AIS1020CR [9]. The skeleton is shown in
figure 1.

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Figure 1: Basic Structure of the Vehicle Frame

The tests are carried out based on following procedure and parameters. Consider the vehicle hits an inelastic fixed
object, for example, concrete wall. The four components of force are: magnitude, direction, point of application, and line of
action Weight of Vehicle M: 180kgf (Driver weight = 60kgf), Speed of Vehicle v: 40km/hr = 12m/s, Time on impact t:
1/10th of a second.

Consider the total mass of vehicle as a single unit. The impact force is determined by using equation 1 and mass
might be calculated according to equation 2.

The acceleration is calculated using equation 3 and the impact force on the wall is also calculated,

where, Vo is velocity after impact i.e. 0 m/s, V1 is velocity before impact i.e. 40km/hr = 12m/S and t is the time on
impact i.e. 0.1S. The impact force is 14 times the weight of the vehicle. For this calculated force, the frame is tested and it
is shown in figure 2 and the parameters from testing are listed in table 1.

(a) (b) (c)

Figure 2: Frame Testing (a) Rear Impact; (b) Front Impact; (c) Front Impact

Table 1: Impact Test Parameters

Impact Test Min. FOS Max. Displacement (URES) In mm Max. Stress Axial and Bending
FRONT 4.3 160 550 MPa

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1258 M. Premkumar, JSV. Sivakumar, R. Vijaya Krishna & R. Sowmya

REAR 2.2 190 650 MPa

SIDE 5.4 1.731 140 MPa

Torsion test is conducted on the frame to determine the rigidity of the frame and ensures safety in real time. One
side of the frame is fixed and load is applied on the other side. The simulation is done with load of 1000N. The result is
expressed as Torsional stiffness, i.e. how much moment the frame requires to undergo 1o of deflection and it is calculated
as per equation 5.

where, M is moment in N-m and Ɵ is deflection angle. The moment is calculated by multiplying force and
distance. For example, M = force*distance = 1000N * 1.016m = 1016N-m. The deflection angle is calculated from figure
3. The Torsional stiffness according to equation 5, K= 1016/4.39 = 232N-m/degree.

Figure 3: Calculation of Deflection Angle

Table 2: Torsional Test Parameters

Test Front Torsion Back Torsion Full Torsion
Minimum FOS 2.8 2.34 2.4
Maximum displacement 76.79mm 40.37mm 77.34mm
Torsional Stiffness 210Nm/deg 254Nm/deg 232Nm/deg
Maximum Stress – Axial and Bending 240MPa 180MPa 235MPa
Maximum Stress - Torsion 160MPa 90MPa 140MPa

The static loading test is also conducted on the frame. Load carrying capacity of the vehicle is tested at the load of
1000N. Figure 4 shows the static loading test on the frame. For the load of 1000N, the minimum FOS is calculated as 2.1
and the maximum displacement of 13.84mm.

Figure 4: Static Loading Test at 1000N Load

Circular beam test is also conducted on the frame. The frame tube is heated and bent to a circular structure as
shown in figure 5.

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Design, Analysis and Fabrication of Solar PV Powered BLDC Hub Motor Driven Electric Car 1259

Figure 5: Upper Bound Axial and Bending at Deformation Scale of 1568.65

It is having advantage of load gets distributed evenly as there is no sharp curves and ability to bead more load and
take in more stress before deformation. The comparison of circular beam and straight beam is listed in table 3.

Table 3: Comparison Study at Load of 250N

Parameters Curved Beam Straight Beam
Max. Stress N/mm2 72 94
Min. FOS 12.2 8.4

From the comparison table, curved beam is preferred for the frame structure. The frame structures are bent inward
o o
to 1 -2 . This helps the beam to bend inward instead of bending outward. Bending outward can create cracks easily in the
weld as it induce tensile stress. Curving inward induces compressive stress, which can be absorbed by a cross member.

2.2 Suspension System

When the vehicle is about to turn for certain degrees, the wheel on the inner side while turning experiences the
maximum load than the outer side. This load might damage the wheels, frame etc. To avoid this or to minimize this, the
suspensions are used. They are mainly used to enhance the comfort of the passengers, but it also helps in reducing the
direct load to the frame [10].

2.2.1 Front Suspension

Initially, the dimension for the front track width is selected as 65 inches and it will offer resistance to the
overturning moment at the Center of Gravity due to the inertial force and at the tires due to lateral weight transfer. The
wheel base decides the longitudinal weight transfer during braking and acceleration. Finally, we get to know about the
packaging of the components in the vehicle. So, it is decided to keep a wheelbase of 71 inches. Tyre generates the
cornering force necessary during the turns. Its selection will have an effect on the performance of the vehicle. Due to the
availability and economic design, the front wheel is having non geared two wheeler tyre and rear wheel is having YO
speed bike tyre. The average pressures of the tires are 25psi at the front and 35psi at the rear. By keeping the above
constraints, the front suspension is selected as a double wishbone suspension system. The kinematic analysis of double
wishbone suspension system is done as shown in figure 6 and the values obtained from diagrammatic representation of the
wishbones is shown in table 4.

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1260 M. Premkumar, JSV. Sivakumar, R. Vijaya Krishna & R. Sowmya

(a) (b)
Figure 6: (a) Analysis of Double Wishbone Suspension; (b) Front Suspension System

Table 4: Kinematic Analysis

Chang E Chang E Chang E Chang E Variation

For
in Angle in Angle in Angle in Angle in Length
Dive
A B C Q L
-1 7 7.5 88 80 14
-0.7 10 13.5 88 85 13.6
-0.2 12 21 88 90 12.9
0.1 5 14 30 88 95 12.6
0.7 16 41 88 100 11.9

The roll centre is placed below the ground level with a value of -5.31 inches. The reason for negative value of the
roll centre is that during cornering the rolling force is very minimal when the roll centre is negative. The approximate
density of light mineral oil ᵨ, is 860 kg/m³. The thermal expansion of the fluid is, at T= 40°C, ᵨ=851.4 kg/m³, at T= 50°C,
ᵨ=842.8 kg/m³, at T= 60°C, ᵨ=834.2 kg/m³. The compressibility of the suspension is, at P= 5MPa, ᵨ= 862.82 kg/m³, at P=
6MPa, ᵨ= 863.39 kg/m3, at P= 7MPa, ᵨ= 863.97 kg/m³. The approximate viscosity of the fluid is 40.

2.2.2 Rear Suspension

The rear suspension is designed with oil damper suspension and it is shown in figure 7 (a). With a mono-shock
rear suspension, a single shock absorber connects the rear swing arm to the motorcycle's frame. Typically this lone shock
absorber is in front of the rear wheel, and uses a linkage to connect to the swing arm. Such linkages are frequently designed
to give a rising rate of damping for the rear. The spring rate calculation is presented with known input parameters and it
shown in figure 7 (b)-(c).

(a) (b)

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(c) (d)
Figure 7: (a) Rear Mono-Shock Suspension System; (b) Input Parameter for Spring Rate Calculation;
(c) Output Parameters of Spring Rate Calculation; (d) Optional Spring Rates

2.3 Steering System

By taking less weight and steering ratio into consideration, the vehicle is designed with a steering system called
Pitman Arm steering. The selection of steering system based on various parameters and it is listed in table 5.

Table 5: Selection Parameters for Steering System

Parameter Pitman Arm Rack And Pinion
Fewer complexes. More complex than pitman arm.
Complexity
Can be easily machined. System of gears is used.
Contacting surfaces are less which leads More wear and tear takes place due to
Durability
to high durability. gears.
Vibration Vibration is less. More vibration is transferred
Less weight compared to other steering
Weight More weight.
systems.
Quick turns can be achieved in sharp During turning 3 to 4 complete
Turning
corners since the steering ratio used is revolutions are required from lock to
Sensitivity
1:1- 1:2 lock.

The steering ratio is a ratio between the steering wheel turning angle to the wheel turning angle. The steering ratio
of 1:1.126 is selected for this vehicle. i.e., the wheel turning angle is same as that of the steering wheel. The circular arc
formed by the turning path radius of the front outside tire of a vehicle is called turning radius r and it is selected as
240inches and it is shown in figure 8.

Figure 8: Turning Radius

The various parameters of steering parameters are selected by considering advantages and figure 9 will give a
detailed explanation on steering parameters. The angle of the wheel with respect to the vertical axis from front view is
called negative camber angle and it is selected as 20 and for the neutral camber, it is 00. Steering axis inclination / King pin
inclination is 5O with positive inclination, toe in angle of 10 Positive, max steering wheel angle is 900 for each side,

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1262 M. Premkumar, JSV. Sivakumar, R. Vijaya Krishna & R. Sowmya

maximum turning angle is fixed as 710 and finally, King pin to wheel axle orientation is selected as neutral.

(a) (b) (c)

(d) (e) (f)

Figure 9: (a) Negative Camber; (b) Neutral Camber; (c) Steering Axis Inclination; (d) Toe Angle;
(e) Wheel Axle Orientation; (f) Response form Suspension Analyzer

A good steering system must satisfy Ackerman condition. During turns slight variation is unavoidable. Large
variation will lead to steering system failure. The figure 9 (f) shows the variation of Ackerman in the amount of steering.
This was analyzed using suspension analyzer giving condition as steering. From figure 9(f), it is clear that the Ackerman
variation/error is minimal under steering which represents a good steering system design. The steering system is fixed in
vehicle as per the diagram shown in figure 10.

Figure 10: CAD Model of Steering System

2.4 Braking System

The brakes are one of the most important control components of the vehicle. They are required to stop the vehicle
within the smallest possible distance and this is done by converting the kinetic energy of the vehicle into the heat energy
which is dissipated into the atmosphere. In this vehicle, two disc brakes are used on the front axle to be more effective and
drum brake on rear axle assisting to slow or stop the vehicle instantly after applying the brakes. Tandem master cylinder is
used as a master cylinder in a vehicle, because the tandem master cylinder transforms applied brake force into hydraulic

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Design, Analysis and Fabrication of Solar PV Powered BLDC Hub Motor Driven Electric Car 1263

pressure which is transferred to the wheel units through two separate circuits. This provides residual braking in the event of
fluid loss.

Figure 11: Braking Circuit

In braking circuit as shown in figure 11, the two independent lines from the tandem master cylinder are actuated
by single pedal for locking the two wheels on front effectively. And also provide another one pedal for locking the rear
wheel with drum brake. In a disc brake, the brake pads squeeze the rotor instead of the wheel, and the force is transmitted
hydraulically instead of through a cable. Friction between the pads and disc slows the disc down. The parts are taken from
various vehicle and table 6 shows the parts and their respective vehicle.

Table 6: The Various Parts of Braking System

Part Name Qty. Manufacturer

Tandem master cylinder 1 Maruti Omni
Disc (or) Rotor 2 Pulsar150 (Pearlitic Gray CI)
Caliper 2 Pulsar 150
Actuation Pedal 2 Maruti Omni Actuation pedal
Brake Lining - Maruti Omni brake hoses
Brake Fluid - Dot 3

By considering the various issues in designing a proper braking system, the various parameters are calculated with
some design consideration. The table 7 shows the braking parameters and the braking efficiency of the vehicle is calculated
as per equation 6.

Table 7: Braking Parameters

Sl. No Parameters Calculated Value
1 Pedal Ratio 6:1
2 Pedal Force 305.58 N
3 Fluid Pressure 5.29 * 106 N/m2
4 Clamping Force 9606.64 N
5 Brake Force 4803.32 N
6 Braking Torque 432.3 N-m
7 Deceleration of the vehicle 19.92 m/s2
8 Stopping Distance 2.37 m
9 Stopping Time 0.96 sec
10 Efficiency 65% (Fair)

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1264 M. Premkumar, JSV. Sivakumar, R. Vijaya Krishna & R. Sowmya

2.5 Ergonomics

Ergonomics refer to the design factors, as for the workplace, intended to maximize productivity by minimizing
operator fatigue and discomfort. Vehicle is properly designed to give additional safety and comfort. Egress time depends
on position of the driver. Driver’s comfort depends on the position he sits. A good position can make a driver go long
drives without any fatigue and stress and enjoy the drive. The position shown in 12(a), seat must provide comfort and
shouldn’t allow driver to slip in turns. If the weights must also lie close as possible to the CG point, so that vehicle spin
with respect to vertical axis is used which gives additional advantage while steering by overcoming under steering.
The figure 12(b) shows the concept of weight distribution affecting handling. The following problem arises when the
placement of battery, 1. Placing inward – more vehicle spin; 2. Placing outward – more moment in turns. So the batteries
are placed to balance out both these effects.

(a) (b) (c)

Figure 12: (a) Seating Position; (b) Weight Distribution; (c) Solar Panel Placement

In order to minimize the under-steering, the batteries are closed in near CG point. Space for the driver must also
be considered. The solar panel placement is also crucial role and it is shown in figure 12(c). Totally 3 panels are used.2
panels are placed on top with 50inch high and one in front. Totally 50squarefeet of panels are used. Panels are placed with
the following consideration: 1. Maximum sunlight reception; 2. Aerodynamics of the vehicle; 3. Convenience for the
driver. The ends of solar Panel are made into curves with a thin gauge sheet metal to reduce air drag. The more weight on
the forward wheels, the better the cornering and less over-steer. However, too much weight on the front wheel causes the
rear wheel to wash-out during hard cornering or cause the trike to end-over during braking. Driver’s visibility is restored to
2200. Additionally, 2 rear view mirrors are provided to check the other 140o is provided to 2 rear view mirrors on either
side. Driver will have a clear visibility of 360o.

3. DESIGN AND TESTING OF ELECTRICAL SYSTEMS

The overall block diagram of electrical system is shown in figure 13. The vehicle is powered with solar PV panel
through MPPT charge controller to extract more power from the solar PV module and battery source. The motor is
supplied with battery power and solar module power individually and it is controlled by changeover switch.

Figure 13: Flow Diagram of Electrical Systems

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3.1 Solar Panel with MPPT Charge Controller

All over the world there is significant increase in usage of solar energy. Fuel replaced by Solar panel. All the
automobile companies have their project works –going in solar power to run vehicles in solar energy. Based on the design
of solar panel, the entire vehicle is designed because of it being the most dominating feature. The power rating of the motor
is 700W. So, the solar PV is designed with 750W by keeping 50W as tolerance. The total number of PV panel used in this
vehicle is 3 and each having 250W.

The specification of solar PV is as follows. Maximum voltage from one cell is 0.666V, the available size of 48V
solar panel for all 3 panel is 49 Square feet, maximum voltage from one 72 cells of solar panel at open circuit is 59.5V, the
maximum voltage output at average condition of sunlight is 48.5V, maximum current from one 72 cells of solar panel at
open circuit is 8A, the maximum current output at average condition of sunlight an short circuit is 5.15A, the maximum
power output from a solar panel at average condition of sunlight is 250Wand maximum power output from 3 solar panel
output is 750W.

Figure 14: Block Diagram of Electrical Systems

A MPPT, or maximum power point tracker is an electronic DC to DC converter that optimizes the match between
the solar array (PV panels), and the battery bank or utility grid and block diagram is shown in figure 14 [5], [13]. To put it
simply, they convert a higher voltage DC output from solar panels (and a few wind generators) down to the lower voltage
needed to charge batteries.

3.2 BLDC Hub Motor

The vehicle designed with 750W BLDC motor (brushless DC). BLDC motor is a type of synchronous motor,
where magnetic fields generated by both stator and rotate have the same frequency. The BLDC motor has a longer life
because no brushes are needed. Apart from that, it has a high starting torque, high no-load speed and small energy losses.
Out of many configurations, three phase motors are the most popular and are widely used in e-bikes. The vehicle is
selected with hub motor because the motor replaces the hub of wheel. Coupling loss is reduced and mounting can be made
easy without the use of chains or belts, and that reduces size and weight of the car.

Figure 15: BLDC Hub Motor

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1266 M. Premkumar, JSV. Sivakumar, R. Vijaya Krishna & R. Sowmya

Diameter of wheel is 10 inches and radius of the wheel is 0.127m is selected for a test drive. The various test on hub motor
is conducted and test results are shown in table 8 and characteristics are shown in figure 16. The test is conducted with
200kg and 300kg load.

Table 8: No Load and Load Test Data on Hub Motor

Sl. Weight Speed Speed Load Current
No (kg) (Kmph) (rpm) (A)
1 10 208.9 4.1
2 20 417.9 4.1
No Load
3 30 626.9 4.1
4 40 835.8 4.1
5 10 208.9 10
6 20 417.9 15
200
7 30 626.9 16
8 40 835.8 25
9 10 208.9 18.5
10 20 417.9 27.5
300
11 30 626.9 28.1
12 40 835.8 29.5

(a) (b)
Figure.16: Performance Characteristics, (a) Torque in Nm Vs Speed in rpm;
(b) Speed in rpm Vs Load Current in A

3.3 Battery Unit with Charging Parameters

Battery based renewable energy systems vary greatly in size and design based on the purpose and location of the
installation. Unlike many other battery applications, this battery based renewable energy applications are unique because
the batteries can be discharged and then charged in a very unpredictable manner due to variations in sunshine. Deep cycle
valve regulated Lead-Acid batteries (VRLA) or sealed battery is the best choice for renewable energy applications but it is
also recognized that there are different types having strengths and weaknesses which influence their suitability and life
[11]. This solar car utilizes lead acid battery and four lead-acid batteries will be connected in series to drive a hub motor
through a controller. To maintain the stability of the car in the best possible way the batteries are split up into four and
placed in the most comfortable region. The batteries are charged with 48V, 2.5A, charger circuit which is powered by solar
panel (1000W).

The vehicle is designed with four 12V batteries which are connected in series; hence the input voltage should be
48Vat the minimum. Since the charging potential should be greater than battery potential we boost up the voltage level to
50Vor more. The minimum charging current should be 10% of rated battery current. So, the charging current for the
battery is 3.3A. Considering the lifetime of battery, charging current is also boosted up to 3.5Aor more. The time taken for

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the 33AH batteries to charge is 9.4 hours. However, it is impossible to charge the battery without any efficiency loss, hence
the following table 9 shows the time taken to charge with efficiency loss. The time taken to discharge depends on the load
current. The maximum current that the motor will draw under full load is 16.6A. So, the discharge time is 1.16 hours (on
full load). The graph is shown in figure 17 is plotted to show the capacity of battery at the different charging interval at
27oC temperature.

Table 9: Charging Time with Various Efficiency Loss

Maximum Time To Full Charge (10% Efficiency Loss) 10.3 Hours

Maximum Time To Full Charge (20% Efficiency Loss) 11.3 Hours
Maximum Time To Full Charge (30% Efficiency Loss) 12.4 Hours
Maximum Time To Full Charge (30% Efficiency Loss) 13.4 Hours
Maximum Time To Full Charge (No Efficiency Loss) 9.6 Hours

(a) (b)
Figure 17: (a) Battery Wiring Diagram; (b) Capacity of Battery with Different Charging Interval

3.4 Electronic Speed Control Unit of Hub Motor

A motor controller is a device or group of devices that serves to govern, in some predetermined manner, the
performance of an electric motor. A motor controller might include a manual or automatic means of starting and stopping
the motor, selecting forward or reverse rotation, selecting and regulating the speed, regulating the speed, regulating or
limiting the torque, and protecting against overloads and faults. It is the brain of the vehicle and it is a multi-functioning
device. On receiving battery voltage, it activates. It provides signal voltage to all major electronic components like
accelerator, brake, motor, etc. and it uses Hall Effect sensors to direct the rotor’s position [12]. The specification is shown
in table 10.

Table 10: Specification of Electronic Speed Controller

Input 48 volts DC from battery
Output AC 5 volts to the system.
Hall Sensor Type 60o or 120o (60o is used here)
Electric Signal AC Pulse
Type Of Output 5V SYSTEM (Overload indication, lights, hall censors)
Min. O/P Voltage 20 volts
Full Load Current 20 A

The controller for receiving the accelerator signal, the controller supplies power from battery to motor. Because
the controller must direct the motor’s rotor rotation, the controller needs some means of determining the rotor’s position.

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1268 M. Premkumar, JSV. Sivakumar, R. Vijaya Krishna & R. Sowmya

There by using Hall Effect sensors we will be able to directly measure the rotor’s position. The controller contains 3 bi-
directional drivers to drive high-current DC power, which are controlled by a logic circuit. Position information can be
gotten by Hall Effect sensors that detect the rotor magnet position. By pressing the accelerator, the hall sensor mounted
inside the accelerator sends signal to the controller. The controller sends power to the motor proportional to the pressing
force of the accelerator. The speedometer shows indication proportional to the pressing force of the accelerator. Borax
contains electronic sensors in the form of pedal. It receives signals from the controller. On applying the brake, the signal is
sensed by the controller and controller stop sending power to the motor. It saves power when frequent braking situation
arises. The speed control unit is shown in figure 18.

Figure 18: Interior View of Electronic Speed Controller

RESULTS AND DISCUSSIONS

The car requires more torque and acceleration. The hub motor develops maximum torque at low rpm, then torque decays
with speed in steps with car natural demand. Solar power from solar PV is limited by the size of the car and area that can
be exposed to sunlight. While energy can be accumulated in batteries to lower peak demand on the array and provide
operation in sunless conditions. SEPHV is combined technology of solar and electric power. Solar vehicle depends on PV
cells to convert sunlight into electricity to drive electric motors. The weight estimation of the proposed vehicle is listed in
table 11 and chart is shown in figure 19.

Table 11: Weight Estimation of Proposed Car

Department Weight(Kg)
Motor and Controller 11.5
Solar Panel and Charge Controller 51
Batteries and Accessories 29
Frame, Base & Weld 26
Steering System 2
Braking System 9.3
Ergonomics 6.15
Miscellaneous 11.5
Driver Weight 60
Overall Weight of Car 206.45

Figure 19: Weight Estimation Chart

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Speed is controlled through accelerator pedal which is connected with electronic speed controller. Solar PV panel
is mounted on top of the vehicle and it will charge the batteries via MPPT charge controller. Three 250W solar panels is
used to charging the batteries and it will drive the motor with load nearly 250kg including the weight of driver.
The maximum speed of the proposed car is limited 40kmph. The battery will be continuously gets charged by the solar
panel. During less irradiance, the battery alone will drive the motor and it provides the continuous run for the vehicle.
Figure 20(a) shows the proposed solar car solar vehicles race in India and figure 20(b) shows the battery placement with
safety measures.

(a) (b)
Figure 20: (a) Assembled Electric Solar Car for Race; (b) Placement of Battery

The cost report is presented in figure 21 which will give details on how economically the car is designed and how
the cost is distributed among each part of the vehicle. From the final observation, it is essential to notice the issue related
with the appropriate utilization of solar power during the race. As showed in Figure 20(a), the top roof demonstrates an
inclination of 40o over horizontal axle by the solar tracking system.

Figure 21: Cost Distribution

CONCLUSIONS

The importance of this proposed car is making the shift to the source of energy which is made cost effective, and
utilization of solar power was implemented. The objective of selecting the suitable components was studied and analyzed.
The various components for the same is subjected to various tests which was cross checked with simulation results.
The main features of the proposed design of solar vehicle combine PV energy and human energy. Distinct importance has
been strained to PV solar energy as main power source. The results related to chassis, transmission, suspension, braking,
weight, and all electrical systems were obtained by conducting various test and with simulation tools. The overall cost of
the solar PV is less than other solar PV modules. The research in different stages led to the utilization of lead-acid battery

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1270 M. Premkumar, JSV. Sivakumar, R. Vijaya Krishna & R. Sowmya

because of its characteristics and for its use in electric car especially. Batteries were placed on the back side of the car and
the electric motor is powered through the control circuit. The car can achieve a maximum speed of 45kmph for a distance
of 100 km, depending on energy savings. The car travels without any noise and without any toxic gas emission, it is a
friend of the environment. Conceivable enhancements for the electric vehicle will be planned in future work, taking into
account the zero emission and the incorporating the new technologies as the main strategies.

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