International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

The efficiency and technical and economic properties of the electric cars depend mainly on the rechargeable traction battery. LiFePo4 batteries belongs to the lithium-ion type and has a number of advantages such as high capacity, long life cycle, resistance to fire at high temperatures or shock. They have safe and stable over-charging and over-discharging performances. This paper describes the process of charging the individual cells of an electric car battery after their over-discharge.

The present paper is focusing on a basic research for an initial design of an internal combustion engine for use in a range extender unit for an electric vehicle. The paper introduces a short description of the power train concept as well some interesting points, problems and challenges during the design process of the internal combustion engine. Some of them are connected with a proper selection of the engine configuration (number of the cylinders, their configuration, etc.), a determination of the engine main parameters (bore and stroke) and how they affect the engine operation and performance. Different parametric models are used and some output results are presented.

The automotive industry is facing new challenges in the electric vehicle segment. It is relevant to conduct joint research of various vehicle systems in a common virtual physical environment, which will allow combining a large number of test rigs located in different parts of the world. A common virtual physical environment, called X-in-the-loop, was developed, as a part of these studies. The work involves the joint connection and use of test rig for various purposes, software simulators, driving simulators, etc., to conduct a comprehensive study of the components and systems of electric vehicles in real time. The development of the thermostating system for highvoltage components is an urgent and important task when creating modern electric vehicles. A test rig was created at FSUE NAMI to study the operation of the thermostating system for high-voltage components of an electric vehicle’s traction drive. The test rig includes a physical simulation of high-voltage components of the traction drive of an electric vehicle from the point of view of temperature and hydraulic conditions of the components studied at other test rigs included in the XIL experiments. The scientific article presents the concept of a developed test rig. The article also describes the test modes that were necessary to conduct research on various components and systems of electric vehicles in various conditions. The article describes a method for controlling the actuators of the thermostating system and devices designed to reproduce the thermal and hydraulic characteristics of cooled objects (motor-wheels and inverters) in real time. A test rig for the study of the thermostating system of high-voltage components, modelling, prototyping and testing were carried out in the process of developing.

This report examines the characteristics of powerful supercapacitors, which are used in electric vehicles to perform their driving dynamics, as well as to power starter motors of powerful internal combustion engines in large trucks, military vehicles and more. Main requirement for supercapacitors is tobe able to deliver a large amount of electricity for about ten seconds, and for very powerful motors (over 100 kW) – for up to 15 seconds. Various technological methods have been reported for supercapacitorsproduction, including the onedeveloped by the current authors, which is based on a ceramic dielectric with a high relative dielectric constant.

The development of temperature control system of high-voltage batteries is an actual and important task in the development of modern electric and hybrid vehicles. There are a large number of designs and types of temperature control systems. In this article, we propose to consider a temperature control system based on a liquid cooling system and designed for both cooling and heating the battery in a wide range of ambient temperatures. In the development process of temperature control system for high-voltage batteries were carried calculations, 3D modelling of the design and tests.

In recent years, many researches in the field of electromobile transport using as driverless vehicle are carried out in Russia as in the world. Operation electromobile transport in Russia has specific features, among which are the cold climate and heavy traffic conditions. One of the key elements of the functioning of electromobile transport is an energy storage system, the characteristics of which are highly dependent on how and under what conditions the vehicle is operated. The life of the energy storage system is also adversely affected by high temperature and short overvoltage on its elements. To increase the mileage of vehicles on the electric energy storage provides an improved system design, and in this article the experience of creating such an energy storage system for the driverless vehicle, taking into account including the Russian operating conditions. In the process of creating energy storage system were carried out calculations, mathematical and natural layout the basic elements of the system.

The launch of electric vehicles and ITS initiated new challenges for design related ergonomics in the vehicles, especially in the field of Human Machine Interface (HMI). This research is motivated by the necessity for evaluation of current ergonomic and design solutions of contemporary vehicles. The presented study included a review of available literature and regulations, state of the art, as well as operational analysis based on detailed comparison between two vehicles. The assessment has been done between two existing vehicles of the same model, the first one powered by the internal combustion engine, and the other one powered by an electric engine. The information displays, vehicle controls and secondary vehicle controls of both vehicles were carefully analyzed and compared. The results of the study are presented as a source of preliminary understanding of the newly developed technology for designers, experts dealing with safety issues and other professionals.