The Science of Electric Vehicles: Concepts and Applications

233 Pages·2023·7.819 MB·English

by  Frank R. Spellman

The Science of Electric
Vehicles
The Science of Electric Vehicles: Concepts and Applications presents the basic elec-
trical principles, physics, chemistry, use of rare earth elements (REEs), batteries,
charging, and operation of motor controllers of EVs. In addition to the general con-
cepts, the book examines the policies and economics pertinent to the move from
hydrocarbon power to electric-powered vehicles. It covers the history and develop-
ment of electric vehicles as well as the science and engineering behind them.
Features:
• Presents the basic electrical principles, physics, and chemistry involved in
the manufacture of electric vehicles.
• Discusses various battery types, energy efficiency, storage, and more.

The Science of Electric
Vehicles
Concepts and Applications
Frank R. Spellman
Designed cover image: Shutterstock | Gorodenkoff
First edition published 2023
by CRC Press
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Library of Congress Cataloging‑in‑Publication Data
Names: Spellman, Frank R., author.
Title: The science of electric vehicles : concepts and applications / Frank
R. Spellman.
Description: First edition. | Boca Raton : CRC Press, 2023. | Includes
bibliographical references and index. |
Identifiers: LCCN 2022044179 (print) | LCCN 2022044180 (ebook) |
ISBN 9781032366289 (hardback) | ISBN 9781032366296 (paperback) |
ISBN 9781003332992 (ebook)
Subjects: LCSH: Electric vehicles.
Classification: LCC TL220 .S647 2023 (print) | LCC TL220 (ebook) |
DDC 629.22/93–dc23/eng/20221206
LC record available at https://lccn.loc.gov/2022044179
LC ebook record available at https://lccn.loc.gov/2022044180
ISBN: 978-1-032-36628-9 (hbk)
ISBN: 978-1-032-36629-6 (pbk)
ISBN: 978-1-003-33299-2 (ebk)
DOI: 10.1201/9781003332992
Typeset in Times
by codeMantra
Contents
List of Acronyms and Abbreviations ........................................................................xi
Preface......................................................................................................................xv
Author ....................................................................................................................xvii
Chapter 1 Electric Vehicles (EVs) .........................................................................1
Introduction ..........................................................................................1
Chapter 2 Electron Flow = Traffic Flow ...............................................................3
Back in the Good Old Days ..................................................................3
How Times Have Changed ...................................................................3
Chapter 3 Basic Electricity ...................................................................................7
Introduction ..........................................................................................7
Nature of Electricity .............................................................................7
The Structure of Matter ...................................................................8
Conductors .........................................................................................11
Unit Size of Conductors .................................................................11
Square Mil .....................................................................................12
Circular Mil ...................................................................................12
Circular-Mil-Foot ..........................................................................14
Resistivity ......................................................................................14
Wire Measurement ........................................................................16
Factors Governing Selection of Wire Size ....................................16
Copper vs. Other Metal Conductors ..............................................18
Temperature Coefficient (Wire).....................................................18
Conductor Insulation .....................................................................20
Conductor Splices and Terminal Connections ..............................20
Soldering Operations .....................................................................20
Solderless Connectors ....................................................................21
Insulation Tape ..............................................................................21
Static Electricity ............................................................................21
Charged Bodies .............................................................................22
Coulomb’s Law ..............................................................................22
Electrostatic Fields ........................................................................23
Magnetism .....................................................................................24
Magnetic Materials ........................................................................25
Magnetic Earth ..............................................................................26
Difference in Potential...................................................................27
Water Analogy ...............................................................................28
Principal Methods of Producing a Voltage....................................29
v
vi Contents
Electric Current .............................................................................31
Resistance ......................................................................................32
Electromagnetism ...............................................................................33
Magnetic Field Around a Single Conductor ..................................34
Polarity of a Single Conductor ......................................................35
Field Around Two Parallel Conductors .........................................35
Magnetic Field of a Coil ................................................................36
Polarity of an Electromagnetic Coil ..............................................37
Strength of an Electromagnetic Field ............................................37
Magnetic Units ..............................................................................38
Properties of Magnetic Materials ..................................................39
Permeability ..............................................................................39
Hysteresis ..................................................................................39
Electromagnets ..............................................................................40
One More Word ..................................................................................40
Chapter 4 Battery-Supplied Electricity ...............................................................41
Basic Battery Terminology .................................................................41
Battery Characteristics .......................................................................42
Voltaic Cell .........................................................................................43
Primary and Secondary Cells .............................................................44
Battery ................................................................................................45
Battery Operation ...............................................................................45
Combining Cells .................................................................................46
Types of Batteries ...............................................................................47
Electric Vehicle Terminology .............................................................50
One More Word ..................................................................................51
Reference ............................................................................................51
Chapter 5 AC Theory ..........................................................................................53
Introduction ........................................................................................53
Basic AC Theory and Principles .........................................................53
Basic AC Generator .......................................................................55
Cycle ..............................................................................................55
Frequency, Period, and Wavelength ..............................................57
Characteristic Values of AC Voltage and Current ...............................58
Peak Amplitude .............................................................................58
Peak-to-Peak Amplitude ................................................................58
Instantaneous Amplitude ...............................................................59
Effective or RMS Value ................................................................59
Average Value ................................................................................60
Resistance in AC Circuits ..............................................................61
Phase Relationships .......................................................................63
Inductance .....................................................................................64
Inductance: What Is It? ..................................................................64
Unit of Inductance .........................................................................65
Contents vii
Self-Inductance ..............................................................................66
Growth and Decay of Current in an RL Series Circuit .................68
Mutual Inductance .........................................................................69
Calculation of Total Inductance ....................................................70
Capacitance ...................................................................................71
The Capacitor ................................................................................71
Dielectric Materials .......................................................................73
Unit of Capacitance .......................................................................75
Factors Affecting the Value of Capacitance ..................................76
Voltage Rating of Capacitors .........................................................77
Charge and Discharge of an RC Series Circuit .............................78
RC Time Constant .........................................................................79
Capacitors in Series and Parallel ...................................................79
Types of Capacitors .......................................................................81
Ultracapacitors ...............................................................................82
Ultracapacitor Operation ...............................................................82
Inductive and Capacitive Reactance ...................................................83
Inductive Reactance .......................................................................83
Capacitive Reactance .....................................................................86
Phase Relationship of R, L, and C Circuits ...................................87
Impedance .....................................................................................88
Power in Reactive Circuits ............................................................89
Series RLC Circuit ........................................................................89
Parallel RLC Circuits ....................................................................91
Power in AC Circuits .....................................................................92
Reference ............................................................................................94
Chapter 6 Fundamental Physics Concepts ..........................................................95
Introduction ........................................................................................95
Resolution of Forces ...........................................................................96
Slings .............................................................................................99
Inclined Plane ...............................................................................102
Properties of Materials and Principles of Mechanics .......................105
Properties of Materials .................................................................105
Friction .........................................................................................110
Pressure ........................................................................................110
Specific Gravity ............................................................................110
Force, Mass, and Acceleration .....................................................111
Centrifugal and Centripetal Forces ..............................................111
Stress and Strain ...........................................................................112
Principles of Mechanics ...................................................................112
Statics ...........................................................................................112
Welds ............................................................................................113
Dynamics ......................................................................................113
Hydraulics and Pneumatics—Fluid Mechanics ...........................113
References ........................................................................................113
viii Contents
Chapter 7 Dynamics of Vehicle Motion ............................................................115
Factors Affecting Vehicle Dynamics ................................................115
Vehicle-on-Wheels Layout ...........................................................116
Powertrain ....................................................................................116
Braking System ............................................................................116
Geometry of Suspension, Steering, and Tires ..............................116
Pure Dynamics .............................................................................119
Aerodynamics ...................................................................................119
Weight ...........................................................................................120
Lift ................................................................................................120
Drag ..............................................................................................120
Thrust ...........................................................................................121
Rolling Resistance .......................................................................122
Hill Climbing ..............................................................................123
Linear Acceleration .....................................................................123
Angular Acceleration ..................................................................124
Tractive Force ..............................................................................124
References ........................................................................................124
Chapter 8 Electric Motors .................................................................................125
Motors ..............................................................................................125
DC Motors ........................................................................................126
AC Motors ........................................................................................128
Induction Motors .........................................................................128
Synchronous Motors ....................................................................129
Single-Phase Motors ....................................................................130
Split-Phase Motors .......................................................................130
Capacitor Motors .........................................................................131
Shaded-Pole Motor .................................................................131
Repulsion-Start Motor .................................................................132
Series Motor ................................................................................132
Internal Permanent Magnet (IPM) Motors .................................133
Switched Reluctance Motors (SRM) ...........................................133
Chapter 9 DC/DC Converters ...........................................................................135
Introduction ......................................................................................135
Terminology and Definitions .......................................................135
Non-isolated and Isolated Converter Topologies
(aka Configurations) ....................................................................137
Reference ..........................................................................................138
Chapter 10 Inverters ............................................................................................139
The 411 on Electric Vehicles Inverters .............................................139
Electric Vehicles—Present and Future........................................140
Contents ix
Chapter 11 EV’s Carburetor .................................................................................143
Introduction ......................................................................................143
Controllers ........................................................................................144
Controller Components/Elements ................................................144
Resistors ...................................................................................145
Inductors ..................................................................................146
Capacitors ................................................................................149
Supercapacitors: The Need ......................................................153
Diodes: The One-Way Valves ..................................................154
Transistors ................................................................................154
A Change of State.............................................................................155
DC Controllers..............................................................................156
The Bottom Line ..............................................................................157
References ........................................................................................157
Chapter 12 Regenerative Braking and More.......................................................159
Slowing and Stopping ......................................................................159
The 411 on Regenerative Braking ....................................................159
How Does Regenerative Braking Work? .....................................159
Efficiency Comparison and Contrast ...........................................161
The Bottom Line ..............................................................................161
Chapter 13 Battery Power Alternatives ..............................................................163
Introduction ......................................................................................163
Fuel Cells ..........................................................................................163
Key Terms....................................................................................164
Hydrogen Fuel Cells and Other Types .............................................170
Hydrogen Storage ........................................................................173
How a Hydrogen Fuel Cell Works ...............................................174
Other Types of Fuel Cells .................................................................175
Direct Methanol Fuel Cells .........................................................175
Alkaline Fuel Cells ......................................................................176
Phosphoric Acid Fuel Cells .........................................................176
Molten Carbonate Fuel Cells .......................................................177
Solid Oxide Fuel Cells .................................................................177
Reversible Fuel Cells ...................................................................178
Polymer Electrolyte Membrane Fuel Cells (PEM) .....................178
Parts of a PEM Fuel Cell .............................................................179
Membrane Electrode Assembly ..............................................179
Polymer Electrolyte Membrane ..............................................179
Catalyst Layers .......................................................................180
Gas Diffusion Layers (GDLs) .................................................180
Hardware Components ................................................................180
Bipolar Plates ..........................................................................180
Gaskets .....................................................................................181