Volume 9, Issue 4, April – 2024 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24APR174

Design and Development of

Controller for Electric Vehicle
Yash U. Yadav1; Nikhil B. Kolhatkar2; Abhishek D. Dakawale3; T. V. Deokar4
BE Electrical Student1,2,3; Associate Professor4
Electrical Department, SBPCOE Indapur

Abstract:- In this paper, we designing and developing  Electrical Vehicle

controller and converter for the electric vehicles. In the Electric vehicles are classified in to four main types:
electric vehicle battery is used as the energy source, by
using of this battery operating electric motor. If we Electric vehicles are classified based on the type of
connect this battery direct to motor without any control power source they use and the degree of electrification they
device then it causes some unwanted problems in EV’s. have. There are four main types of electric vehicles:
Because of the output voltage of battery is not suitable to
operating Electric vehicles. Which means without any  Battery electric vehicles (BEVs): These are fully powered
control mechanism the output voltage cannot be by electricity and have no internal combustion engine or
controlled and it will give divergence in output voltage in fuel tank. They rely on a large battery pack that can be
terms of error signal. Its result battery output power will charged by plugging into an external source of electricity.
reduce and therefore the performance of electric vehicle  Plug-in hybrid electric vehicles (PHEVs): These use both
is go down in terms of power torque to drive vehicle. So an internal combustion engine and a battery-powered
in electric vehicle use of control mechanism is mandatory electric motor. The battery can be charged by plugging
to control the output voltage of battery and that can into an external source of electricity or by the engine.
achieve proper power and torque by a proper feedback PHEVs can switch between electric and hybrid modes
control system. But price of the EV’s are to much high depending on the driving conditions.
higher the electric vehicle because of battery, motor and  Hybrid electric vehicles (HEVs): These also use both an
EV Controller. internal combustion engine and a battery-powered electric
motor, but the battery cannot be charged externally. The
Keywords:- Sensors, Motor, Microcontroller. engine is used to drive the vehicle and to charge the
battery when it is low HEVs are more efficient than
I. INTRODUCTION conventional vehicles, but less efficient than PHEVs or
BEVs.
Transportation is very important in for the development  Fuel cell electric vehicles (FCEVs): These use a fuel cell
of a country. it enables the movement of people, goods and to generate electricity from hydrogen and oxygen. The
services. Which helps to growth of various sectors of only emission from FCEVs is water vapor. FCEVs have a
economy. Road transportation is primary mode of high driving range and can be refueled quickly, but they
transportation it consumes 88% sector of total transportation. are expensive and require a hydrogen infrastructure.
To that transportation IC engine vehicles are used. Controller
is used in EV’s to control various actions of motor. A II. LITERATURE SURVEY
controller is a device that controls the speed, torque,
direction, and power of an electric motor that drives an EV. A. Paper 1: “A Study on Recent DC-DC Converters”
It also enables the regenerative braking, which recovers some Sidharth Sabyasachi, Mousumi Biswal's.
of the energy lost during braking. converter is also important This paper presents a study on recent developments in
part of EV it decrees or increase the voltage level according dc-dc converters. All the converters are derived based on the
to required voltage rating. In EV different component are two basic converters such as buck converter and boost
used which operate at low voltage rating and battery output converter. The aims of developing the converters are high
voltage is high it will possible to damage components. efficiency and high gain with fast response. Research work
therefore converter is used in EV’s. But the cost of EV’s is has been grown dramatically to provide the service to the
higher than IC engine vehicles because of cost of battery, mankind.
motor and controller. In this paper we are representing the
design and the development of EV controller and controller B. Paper 2: “Methods of Fast Analysis of DC–DC”-
at cheaper cost and low weight. Górecki, P.; Górecki, K.
The paper discusses the methods of fast analysis of DC–
DC converters dedicated to computer programs. Literature
methods of such an analysis are presented, which deter-
mination of the characteristics of the considered converters in
the steady state and in the transient states.

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Volume 9, Issue 4, April – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24APR174

C. Paper 3: “DC-DC Converters for Electric Vehicles”- adjust the amount of electricity in the windings to change the
Joeri Van Mierlo ,Monzer Al Sakka,Hamid Gualous. speed and torque of the motor.
DC-DC converters can be used to interface the elements
in the electric power train by boosting or chopping the voltage The BLDC motor controller has some advantages over
levels Thus, in this chapter, a comparative study on three a brushed DC motor controller. It is more efficient, reliable,
DC/DC converters topologies (Conventional step-up dc-dc and durable because it does not have any mechanical parts
converter, interleaved 4-channels step-up dc-dc converter that wear out sparks. It also produce less noise and heat.
with independent inductors and Full-Bridge stepup dc-dc
converter) is carried out. The modeling and the control of III. PROPOSED SYSTEM
each topology are presented.
A. Problem Statement:
D. Paper 4: “Controller Design for Electric Motor Derived
Vehicle”- Degu Mena ,Nitin Kumar Saxena *.  Control of Motor Speed:
In this paper, proportional and integral based controller The speed of an electric vehicle (EV) is controlled by
is designed for controlling the output voltage of battery. A PI the vehicle’s controller, which operates between the batteries
based controller is designed and implemented for this electric and the motor. The controller simply regulate DC current
motor derived vehicle in the present paper. Paper flow for DC motors. The accelerator pedal sends a signal to
demonstrates how the results improve in presence of the controller which adjusts the vehicle’s speed by changing
controller circuit for this electric motor derived vehicle. the frequency of the motor. Modern controllers adjust speed
and acceleration by an electronic process called pulse width
 Motor Controller modulation.
In most of EV’s BLDC motor is used a BLDC motor
controller is a device that controls the speed and direction of This creates rotating magnetic fields that are always just
a BLDC motor. A BLDC motor is a type of electric motor ahead or just behind the poles of the motor, depending on the
that does not have any brushes or commutators to transfer direction of motion. The controller also needs to synchronize
electricity to the spinning part. Instead, it uses magnets and the timing of the electrical currents with the position of the
coils to create motion. motor, which can be measured by sensors or estimated by
algorithms.
The BLDC motor controller switches the electricity on
and off in the windings in a specific sequence. This sequence  Control of Battery Voltage
makes the magnetic field of the stator change its direction and The battery voltage in an electric vehicle (EV) is
strength. The changing magnetic field attracts and repels the controlled by a battery management system (BMS), which is
magnets on the rotor, making it spin. The controller can also a device that monitors and regulates the state of the battery
pack.

B. Block Diagram:

Fig 2: Block Diagram of Controller

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Volume 9, Issue 4, April – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24APR174

C. Hardware Requirement:  Implementation and Hardware Integration:

Implement the control algorithms and converter designs
 Microprocessors using microcontrollers, digital signal processors (DSPs), or
 CAN FPGA-based platforms. Develop hardware interfaces for
 Motor speed sensor sensors, actuators, and communication buses to enable real-
 Battrey voltage sensor time control and monitoring. Integrate the control and
 Throttle position sensor converter hardware into the electric vehicle's powertrain
 Breaking Sensor system.
 DC to DC Converter
 Testing and Validation:
D. Fundamental Steps for System Conduct laboratory tests to verify the functionality,
stability, and performance of the controller and converter
under various operating conditions. Perform hardware-in-the-
 System Requirements Analysis:
loop (HIL) simulations to validate the real-time behavior of
Define the electrical specifications of the electric
the system. Ensure compliance with safety standards and
vehicle system, including voltage levels, power ratings,
regulations for electric vehicle components.
efficiency targets, etc.
 Deployment and Maintenance:
Identify the control and conversion requirements such
Deploy the controller and converter systems in electric
as motor control, battery charging, power factor correction,
vehicles for field testing and real-world operation. Monitor
etc.
system performance and reliability through diagnostics and
 System Modeling and Simulation: data logging. Provide firmware updates and maintenance as
needed to address issues and incorporate improvements.
Develop mathematical models for individual
components like motors, batteries, power electronics, etc.,
using circuit theory and electromechanical principles. IV. RESULT
Simulate the models using software tools like
 Input Location
MATLAB/Simulink, PLECS, or LTspice to analyze the
behavior of the system under different operating conditions.

 Control Algorithm Design :

Design control algorithms for motor drives, battery
management systems, and power converters. Choose
appropriate control techniques such as PI control, predictive
control, or sliding mode control based on system
requirements and performance criteria. Implement algorithms
for tasks like torque control, speed regulation, current
limiting, etc.

 Converter Topology Selection and Design:

Select suitable power converter topologies such as
voltage source inverters (VSI), current source inverters (CSI),
or buck-boost converters based on the application
requirements. Design the converter circuits considering Fig 3: Input Page
factors like efficiency, voltage/current ratings, switching
frequency, and component stresses. Optimize the design for
features like soft switching, high-frequency operation, and
compactness.

 Gate Drive and Protection Circuit Design:

Design gate drive circuits to properly control the
switching of power semiconductor devices (e.g., MOSFETs,
IGBTs) in the converters. Implement protection features like
overcurrent protection, overvoltage protection, and thermal
protection to safeguard the converter and connected
components.

Fig 4: Output Page

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Volume 9, Issue 4, April – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24APR174

V. RESULT DISCUSSION VI. CONCLUSION

 Protection Mechanisms. Discuss how the Performance In conclusion, the designing and development of EV
Evaluation: controller and converter for electric vehicles is a challenging
Assess the performance of the controller and converter task that require the information about various component.
in terms of motor drive efficiency, battery charging The EV controller is responsible for controlling the speed,
efficiency, and overall system responsiveness. Discuss how torque, direction, and power of the electric motor. It also
well the control algorithms achieve desired objectives such as support various modes of operations. The electric vehicle
torque control, speed regulation, and battery management. controller is a vital component for electric vehicles, as it
Present experimental data or simulation results to illustrate regulates the speed and torque of the motor according to the
the system's dynamic response under different operating driver’s demand and the vehicle’s operating conditions.
conditions (e.g., acceleration, deceleration, steady-state
driving). REFERENCES

 Efficiency Analysis: [1]. Sidharth Sabyasachi, Mousumi- Biswal's described in

Analyze the efficiency of power conversion processes “A Study on Recent DC-DC Converters” International
within the system, including losses in the converter Journal of Engineering Research and Applications
components (e.g., switching losses, conduction losses). (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2,
Compare the efficiency of different converter topologies and Issue 6, November December 2012, pp.657- 663.
control strategies to identify areas for optimization. Discuss [2]. Górecki, P.; Górecki, K. described in "Methods of Fast
the impact of efficiency improvements on the electric Analysis of DC–DC" Converters—A Review.
vehicle's overall energy consumption and driving range. Electronics 2021, 10,2920..
[3]. Joeri Van Mierlo ,Monzer Al Sakka,Hamid Gualous
 Stability and Robustness: described in “DC-DC Converters for Electric
Evaluate the stability and robustness of the control Vehicles” September 2011.
algorithms under various disturbances and uncertainties. [4]. Degu Mena ,Nitin Kumar Saxena described in
Discuss the effectiveness of control strategies in maintaining “Controller Design for Electric Motor Derived
system stability during transient events such as sudden load Vehicle ” Indonesian Journal of Electrical
changes or voltage fluctuations. Present results from Engineering and Informatics (IJEEI) Vol. 6, No. 2,
sensitivity analysis to assess the system's tolerance to June 2018, pp. 125~131 ISSN: 2089-3272, DOI:
parameter variations and external disturbances. Address the 10.11591/ijeei.v6i2.282 08 November 2021.
safety features implemented in the controller and converter
design, such as fault detection, isolation, and system complies
with relevant safety standards and regulations for electric
vehicle components. Present reliability assessments,
including mean time between failures (MTBF) calculations
or failure mode and effects analysis (FMEA), to demonstrate
the system's reliability in real-world applications.

 Comparison with Requirements:

Compare the achieved results with the initial design
requirements and specifications. Discuss any deviations from
the original requirements and the corresponding implications
on system performance and functionality. Highlight areas
where the system exceeds or falls short of the specified
targets and provide recommendations for future
improvements. Future Directions and Improvements Identify
potential areas for further optimization and enhancement in
the controller and converter design.

Discuss future research directions, such as exploring

advanced control algorithms, optimizing power converter
topologies, or integrating additional functionalities (e.g.,
vehicle-to-grid capabilities). Propose strategies for
addressing emerging challenges in electric vehicle
technology, such as increasing power density, improving
energy efficiency, and enhancing system integration.

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