Trivandrum Engineering Science & Technology Research Park

An Institution of Government of Kerala

Electric Vehicle Centre of Excellence at TrEST Research Park

1.0 Introduction

Trivandrum Engineering Science and Technology (TrEST) Research Park is an institution owned by Government of Kerala to promote partnership and interaction between academic community and industry. The synergy is expected to benefit both and bring about qualitative and quantitative improvements. It is expected that TrEST Research Park will succeed in developing new technologies and foster inventions resulting in new technology companies coming up in the Park in various engineering disciplines. From the State’s perspective, TrEST Park will help in generating high quality employment and help in economic development of the State.

TrEST had signed an MoU with Entuple Technologies,an Engineering Solution company to a establish Centre of Excellence (EV CoE) in the emerging Electric Vehicle (EV) Technologies ( Machines, Drives & Chargers) to carry out research in multidisciplinary focus areas. MoU envisage to effectively share the expertise of the Entuple for improving the capabilities and opportunities for advanced education and research at TrEST. As part of MoU, Entuple had taken up space at TrEST park and a research and development company in Electric Powertrain for electric vehicle was initiated. As per MoU, Entuple had positioned 5 Technical Resources with expertise and experience in the respective fields of EV technologies

The requirement of traction motors for EV application covers electrical performance parameters as well as thermal,vibration and external shock and structural integrity requirements.This is possible only by way of Multiphysics analysis. As part of MoU, TrEST, Ansys & Entuple jointly established the infrastructure needed for research and development activities in EV motors at TrEST. The facilities at TrEST now include Ansys software viz. Ansys Maxwell, Ansys CFD and Ansys Mechanical.

2.0 Joint Research Projects at EV CoE

As per MoU, Entuple had taken up 5 research projects relevant to EV domain with involvement of faculty and engineering students. These projects were picked up from advanced Electric Motor design, Motor Controller & Control system and Charging system. As these research projects have immediate relevance to EV industry, the products developed can be commercialised.

The project team comprises engineers from Entuple, Faculties from CET and Students from Engineering Colleges. In the proposed 5 projects, in total, 19 students shall get opportunity to work as interns. These projects are planned to execute in phased manner. Total duration of the projects is 2 years. First project was already initiated. Synopsis of the proposed 5 projects are given below. India, for its part, is seeking to create a home-grown fabless semiconductor design ecosystem as it realizes that make-in-India objectives cannot be achieved without designing chips that make-up significant portion of the cost of our electronic hardware imports.

2.1 Rare earth magnet free motor with drive for 3W application and its retro fitment

Currently BLDC motors and PMSM are mainly used in EV powertrain because of their lower size and high efficiency over 95%. These motors need high energy permanent magnets made out of rare earth elements which is monopoly of China. Reaseach is happening at different laboratories across globe towards developing motors avoiding rare earth permanent magnets. This project envisage detailed investigation of different types of motors without magnets for EV applications and its development. Accordingly Synchronous Reluctance Motor (SynRM) is selected for development,as part of proposed project.

The team will design & develop the powertrain needed for 3W, required SynRM, its controller and the transmission scheme . Finally he powertrain will be integrated and retro fit the the existing IC engine 3W . The project envisage cost reduction of EV motors, avoid issues related to permanent magnet demagnetisation and dependency on rare earth elements. Project duration is 12 months.

Project team comprises 5 Engineers from Entuple, 4 Faculty members from CET and total 5 student interns from Electrical & Electronics Engineering(EEE) Department and Mechanical Engineering (ME) department. The project started on 7-11-19

2.2 Power dense induction motor design with Heat pipe Based cooling system

Heat pipe based cooling system provide much better efficiency compared to normal liquid cooling system. It is very promising technology for cost effective induction machine for automotive applications. Tesla had already started using this scheme. With adoption of this scheme, power density of the machine can be increased. The project involves design of cooling scheme for 30kW induction motor on heat pipe, thermal modeling, simulation, hardware design and realisation

The project is scheduled to commence on 7-2-2020 with participation of 2 engineers from Entuple, 1 faculty member from CET and 4 student interns from Mechanical Engineering(ME) department of CET. Project duration is 22 months

2.3 Maximum Torque Per Ampere (MTA) along with FOC for range extension of EV.

The project aims at 15% saving in battery usage for same torque resulting extended range with no additional cost. Scheme will be used along with vector control and space vector modulation. This most well known control method in SynRM. Machine d-axis and q axis currents are controlled such that it delivers maximum possible torque . Moreover MTA gives minimum copper loss and maximum efficiency at low speed. For an EV customer it is minimising enegy consumption.

The project work involve designing a motor control scheme to achieve maximum torque per ampere from the available geometry of the drive and perform simulation studies using Ansys multiphysics tools and FPGA/DSP based motor drive.

The project is scheduled to commence on 7-4-2020 with participation of one engineer from entuple, one faculty member from CET and 2 student interns from EEE department of CET. Project duration is 20 months

2.4. Liquid cooled Inverter complying CISPR 25 Standards

The inverters used for 4 wheeler and above applications must be cooled as the foot print is minimum and power to be dissipated is high. Since the inverters are biggest source of EMI,this must comply to the CISPR 25 automotive requirements. The inverters should also maintain packaging scheme IP66 or above. Reliability of the inverter need to be high and safety of the passenger and operating personnel must be ensured.

Project involve Literature review on the requirements to meet CISPR standard, Configuration studies with emphasis on EMI/EMC and Simulation studies. The project is scheduled to commence on 7-5-2020 with participation of one engineer from entuple, one faculty member from CET and 2 student interns from EEE department of CET. Project duration is 19 months.

v). Battery Management System(BMS) for Li-Ion battery.

Any kind of battery needs a good battery management hardware for ensuring life and performance of the battery. Each cell voltage need to be monitored. The BMS currently used in the industry calls for lot of improvements and innovation. This project is designated as a Student-Faculty Project supported by Entuple. Student group comprising 4 to 6 students guided by a faculty member will drive the project.

Project envisage basic understanding the present designs, understand scope of improvement design of the BMS and its development and testing . Project is scheduled to start on 7-7-2020 and duration is 17 months.

3.0 Training & Certification of Engineering Students in specific topics pertaining to CoE

As part of MoU, Entuple shall provide 45 days of formal training per year on Ansys multiphysics software viz. Ansys Maxwell(high frequency&low frequency),CFD and Mechanical. The training is planned in two steps. First step is basic training and second is advanced training. After completion of the basic training, an option for certification on Ansys tools will be made available to the interested students through advanced training by Entuple. At the end of the advanced training, the students will be evaluated through a test in relevant domain and a project work.The successful candidates will be certified by Ansys and are eligible to get absorbed in industry. The total training and certification process will be at free of cost.

Basic course in Ansys Maxwell and Ansys CFD were already conducted for two batches in each each physics. Ansys Mechanical and Advanced courses are now scheduled in middle of December 2019 and middle of January 2020.

4.0 Expert talks in EV industry domain

As part of MoU, Entuple need to arrange expert talks and workshops on “Orientation on automotive standards and expectations” as well as “Orientation on manufacturing of automotive components” senior experts from automotive industry. Talks from Senior experts from Ansys (1 for each physics for introduction to world wide practices) also will be arranged.

5.0 Other scope of activities at EV CoE

  • To provide software usage guidance and enable other companies incubating at the TrEST park to develop their products.
  • Entuple shall provide support and guidance to the other research units/projects in the TrEST at free of cost.

To explore possibilities of conducting joint/collaborative research and consultancy with TrEST along with other agencies including Government agencies.

Hardware In Loop Lab – partnership with National Instruments and Tata Elsxi

The EV Testing lab is proposed to be set up in four phases namely, Signal level, power level (2/3 Wheeler), power level (4 Wheeler) and Training & Support. TrEST Park is authorized by Government as the implementing agency for setting up of HILS lab in CET in consultation with industry experts and faculty of CET.

The Lab is expected to have capabilities in par with Tata Elxsi. NABL accreditation may have an edge over other testing competitors. NI is collaborating with TrEST to enable CET to apply for research funding on next generation automotive applications from SERB, DST, MHRD, MeitY etc. NI have also shown their interest to set up HILS lab in CET in collaboration with TrEST.

MoU with M/S Altair Engineering and M/s ThinkCogent

M/s. Think Cogent is a value added reseller of Altair and proposes to supply Altair Simulation driven Design Solutions for EVs. Their proposal involves purchase of Research license of the software on Altair Hyperworks.

They have identified three projects in the domains

NVH – Development of Artificial Sound Synthesis for EV

Optimization – Light weighting solutions for EV

Crash – Crash impact simulations of battery system.

College of Engineering Trivandrum

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