Batch 5 Vignan

EXPERIMENTAL INVESTIGATION ON A NEW GENERATION
ELECTRIC VEHICLE USING RENEWABLE ENERGY
Project Work Report

Submitted in Partial Fulfillment of the Requirements
for the Award of the Degree of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
By
MAHADAS VAMSI 19L31A0309

MATHA LOVA KUMAR 19L31A0329
RAMBHATLA TANMAYI 19L31A0340
KENGUVA DHRAKSHAYANI 19L31A03A6
Under the Guidance of

Dr. Girish E. Bhiogade
(Associate Professor)
Department of Mechanical Engineering

Vignan’s Institute of Information Technology (A)
(Approved by AICTE and Permanently Affiliated to JNT University, Kakinada)
(Accredited by NAAC with ‘A’Grade &NBA)
Beside VSEZ, Duvvada, Visakhapatnam – 530046
2023
Department of Mechanical Engineering
Vignan’s Institute of Information Technology (A)
Beside VSEZ, Duvvada, Visakhapatnam – 530046
Certificate
This is to certify that the Project work entitled
“Experimental Investigation on a New Generation Electric
Vehicles using Renewable Energy” has been carried out by

Under my Guidance in partial fulfillment of the requirements for

the Award of the Degree of Bachelor of Technology in Mechanical
Engineering of Jawaharlal Nehru Technological University, Kakinada
during the Academic year 2022-23.
Project Guide Head of the Department

Name: Name:
Acknowledgement
I express my deep gratitude to my guide Dr. Girish E. Bhiogade,
Associate Professor, Department of Mechanical Engineering, Vignan’s
Institute of Information Technology, Visakhapatnam for rendering me
guidance and valuable advice always. He has been a perennial source of
inspiration and motivation right from the inception to the completion of this
project.
I am indeed very grateful to Dr. S. Rambabu, Associate Professor and
Head of the Department, Mechanical Engineering, Vignan’s IIT,
Visakhapatnam for his ever willingness to share his valuable knowledge and
constantly inspire me through suggestions.
I sincerely thank all the Staff Members of the Department for giving
me their heart full support in all stages of the project work and completion of
this project.
In all humility and reverence, I express my profound sense of gratitude
to all elders and Professors who have willingly spared time, experience and
knowledge to guide me in my project.

Abstract
ABSTRACT
The vehicles of the modern era are becoming more sophisticated and efficient. Due to the
arrival of EVs on the market, there has been a significant change in the automotive industry
globally. Although some of Humanity's needs are met by EV. However, there are some
drawbacks to EVs as well, which draw people into the field of electrical vehicles. The
primary obstacle is the lack of charging stations, so attention has been paid to this issue and
various approaches have been collected to address it. Ultimately, a suitable solution has been
found that addresses the primary obstacle for EVs. Consequently, some mechanism involved
converts the air resistance that was offered during a vehicle's ride during which wind energy
was converted into electrical energy. The electricity generated from these renewable sources
can be stored in batteries and used to power electric vehicles. In fact, using renewable
energy to power electric vehicles is one of the key advantages of EVs over traditional
gasoline-powered vehicles, as it helps reduce greenhouse gas emissions and promote a
cleaner environment.
Keywords: Electrical vehicle , Solar , Renewable resources , Wind Energy , Self Charge ,
Energy Conversion.
Dept of Mech Engg, VIIT, Visakhapatnam (i)

Table of Contents (Index Sheet)
Chapter Ref. Description Page
No. No No
INTRODUCTION
1.1 Introduction 01
1 1.2 History about Electric Vehicle 01
1.3 Classification 02
1.3.1 Battery Electric Vehicles (BEVs) 04
1.3.2 Plug-In Hybrid Electric Vehicles (PHEVs) 05
1.3.3 Hybrid Electric Vehicles (HEVs) 06
1.3.4 Fuel Cell Electric Vehicles (FCEVs) 07
1.3.5 Extended Range Electrical Vehicles (ER-EVs) 08
1.4 Neighborhood Electric Vehicles (NEVs) 08
1.5 Main Components of Electric Vehicle 09
1.5.1 Battery 10
1.5.2 Electric motor 11
1.5.2.1 Types of Electric Motors 13
1.5.2.2 Permanent Magnet Synchronous Motor 14
1.5.2.3 Induction Motor 14
1.5.2.4 Switched Reluctance Motor 14
1.5.2.5 Brushless DC Motor 14
1.5.3 Power Electronics 15
1.5.4 ON Board Charger 16
1.5.5 Dc to Dc Converter 17
1.5.6 Thermal Management System 17
1.5.7 Regenerative Energy System 17
1.5.8 Electric Control Unit 18
1.6 Working of Electric Vehicle 19
LITERATURE REVIEW
2.1 Review of papers 20
2 2.2 The knowledge gap in earlier investigations 21
2.3 Objectives of the present work 22
EXPERIMENTATION
3.1 Methodology (Experimentation) 23
3.2 Wind Turbine Blade 23
3.2.1 Design of wind turbine blade 24
3.3 Materials used for the turbine blade. 25
3.3.1 Mechanical Properties of PLA and PEEK Material 25
3.3.2 PLA Material 25
3 3.3.3 PEEK Material 27
3.4 Factors in consideration of wind blade design 28
3.5 Design Parameters of Blade in Kinematic Calculator 28
3.5.1 Airfoil Structure 28
3.5.2 Alpha Angle 30
3.5.3 Coefficient of Lift & Coefficient of Drag 30
3.5.4 Airfoil Parameters 31
3.6 Detailed Flow Chart of Working 34
RESULT & DISCUSSIONS
4.1 Static Structural Analysis on Blade 35

4.2 CFD Analysis 42
4
4.3 Practical Experimentation Results 48
4.3.1 Experimental values 48
4.4 Calculation Analysis 48
CONCLUSIONS & FUTURE SCOPE OF WORK
5 5.1 Conclusions 49
5.2 Future scope of work 50
6 REFERENCES 51
ABBREVATIONS
DC Direct Current
AC Alternate Current
EV Electrical Vehicle
HEV Hybrid Electric Vehicle
FCEV Fuel Cell Electric Vehicle
VCU Vehicle Control Unit
PMSM Permanent Magnet Synchronous Motor
IM Induction Motor
SRM Switched Reluctance Motor
CFD Computational Fluid Dynamics
CHAPTER No. LIST OF FIGURES Page No
Chapter No.1
Fig.1.3 Classification of Electrical Vehicles 02
Fig.1.3.1 Battery Electric Vehicle 03
Fig.1.3.2 Plug-in Hybrid Electric Vehicle 03
Fig.1.3.3 Hybrid Electric Vehicle 04
Fig.1.3.4 Fuel Cell Electric Vehicle 04
Fig.1.5.1 Battery 07
Fig.1.5.2 Permanent Magnet Synchronous Motor 09
Fig.1.5.3 Induction Motor 10
Fig.1.5.4 Switched Reluctance Motor 11
Fig.1.5.5 Brushless DC Motor 13
Fig.1.5.6 On Board Charger 15
Fig.1.5.7 Dc to Dc Converter 15
Fig.1.5.8 Regenerative Energy System 17
Fig.1.5.9 Vehicle Control Unit 18
Chapter No.3
Fig.3.1 Design of Blade 40
Fig.3.3 Blade printed with PLA Material 41
Fig.3.5.1 Kinematic Calculator 42
Fig.3.5.2 NACA 4412 AIRFOIL 44
Fig.3.5.3 Kinetic Turbine Power Velocity Graph 45
Fig.3.5.4 Chord Length vs Radius Graph 46
Fig.3.5.5 Twist Angle vs Radius Graph 47
Fig.3.6 Flowchart of working 47
Chapter No.4
Fig.4.1 Meshing 35
Fig.4.2 Maximum Pressure of PEEK Material 36
Fig.4.3 Maximum and Minimum Deformation of PEEK 37
Material
Fig.4.4 Maximum and Minimum Stress of PEEK Material 37
Fig.4.5 Maximum and Minimum Strain of PEEK Material 38
Fig.4.6 Factor of safety of PEEK Material 39
Fig.4.7 Maximum Pressure of PLA Material 40
Fig.4.8 Maximum and Minimum Deformation of PLA Material 40
Fig.4.9 Maximum and Minimum Stress of PLA Material 41
Fig.4.10 Maximum and Minimum Strain of PLA Material 41
Fig.4.11 Factor of safety of PLA Material 42
Fig.4.2.1 Meshing in CFD analysis 43
Fig.4.2.2 Pressure at 40kmph 44
Fig.4.2.3 Velocity at 40kmph 44
Chapter –1
Introduction
Introduction
_________________________________________________________________________________
Chapter – 1 INTRODUCTION
__________________________________________________________________________
1.1 Introduction
Electric vehicles (EVs) are a type of vehicle that is powered by an electric motor and
uses electricity stored in batteries as its primary source of energy. They are becoming
increasingly popular as a more sustainable and environmentally friendly alternative to
traditional gasoline-powered vehicles. EVs are powered by rechargeable batteries, which can
be charged by plugging the vehicle into an electrical outlet or a charging station. One of the
major benefits of electric vehicles is that they produce zero emissions, making them a more
environmentally friendly option than traditional gasoline-powered vehicles. Additionally,
EVs are generally quieter and smoother to drive than gasoline-powered vehicles, and they
can provide significant cost savings over time, as electricity is often cheaper than gasoline.
While electric vehicles have been around for several decades, advancements in battery
technology and the development of charging infrastructure have helped to make them a
more practical and accessible option for consumers. As concerns about climate change and
air pollution continue to grow, it is likely that the demand for electric vehicles will continue
to increase in the years to come.
1.2 History about Electric Vehicle

The history of electric vehicles (EVs) dates back to the early 19th century, when
inventors began experimenting with electric-powered vehicles. In 1835, Thomas Davenport,
an American inventor, built a small electric motor that powered a toy car. In 1837, Robert
Davidson, a Scottish inventor, built a prototype electric carriage that could travel up to 4
miles per hour. In the late 19th and early 20th centuries, electric vehicles became more
popular, particularly in urban areas, as they were quieter and cleaner than gasoline-powered
vehicles. By the turn of the 20th century, electric cars made up around one-third of all
vehicles on the road in the United States. However, the popularity of electric vehicles began
to decline in the early 20th century due to the availability of cheap gasoline and the
Dept of Mech.Engg.,VIIT,Visakhapatnam Page 1

Introduction
introduction of the Ford Model T, which was more affordable than most electric cars at the
time.
In the 1960s and 1970s, concerns about air pollution and oil dependency led to
renewed interest in electric vehicles. Several major automakers, including General Motors
and Ford, developed electric car prototypes, but these vehicles were not widely available to
consumers. In the 1990s, electric vehicles became more commercially viable, with the
introduction of the General Motors EV1 and the Toyota RAV4 EV. However, these vehicles
were only available through lease programs and were not widely marketed or sold.
In the early 2000s, the introduction of the hybrid electric vehicle (HEV), such as the
Toyota Prius, helped to pave the way for increased interest in electric vehicles. In 2008,
Tesla Motors introduced the Tesla Roadster, the first highway-capable all-electric vehicle,
and in 2010, Nissan introduced the Nissan Leaf, the first mass-produced all-electric vehicle.
Today, electric vehicles are becoming increasingly popular, with more and more
automakers introducing new models and advancements in battery technology helping to
extend their range and reduce their cost. It is likely that the trend towards electric vehicles
will continue to grow in the years to come as concerns about climate change and air
pollution become more pressing.
1.3 Classification:
Fig.1.3 Classification of Electrical Vehicles

Electric vehicles (EVs) can be classified into several types based on their powertrain
and driving range. The following are some of the most common classifications:
Dept. of Mech Engg , VIIT ,Visakhapatnam Page 2

Introduction
1.3.1 Battery Electric Vehicles (BEVs):

These are electric vehicles that rely solely on batteries to power an electric motor.
They have no internal combustion engine and produce zero emissions. BEVs typically have
a range of 100-300 miles on a single charge.
Fig.2.3.1 Battery electric vehicle

1.3.2 Plug-In Hybrid Electric Vehicles (PHEVs):
Fig.1.3.2 Plug-in Hybrid Electric Vehicle.

Introduction
These are electric vehicles that have both an electric motor and a gasoline engine.
They can be charged from an external source and can also run on gasoline when the battery
is depleted. PHEVs typically have a range of 20-50 miles on a single electric charge and can
switch to gasoline mode once the battery runs out.
1.3.3 Hybrid Electric Vehicles (HEVs)
These are electric vehicles that have both an electric motor and a gasoline engine, but
the electric motor is used primarily to assist the gasoline engine. HEVs cannot be charged
from an external source and rely on regenerative braking to recharge their batteries.
Fig.1.3.3 Hybrid Electric Vehicle

1.3.4 Fuel Cell Electric Vehicles (FCEVs)
These are electric vehicles that use hydrogen fuel cells to generate electricity to power
an electric motor. FCEVs produce no emissions and have a range of 300-400 miles on a
single tank of hydrogen.
Fig.1.3.4 Fuel Cell Electric Vehicle

Introduction
1.3.5 Extended Range Electrical Vehicles (ER-EVs)

The electric vehicles that have a longer range and can operate at higher speeds. EREVs
use an electric motor as their primary power source, but also have an on-board generator that
can provide additional electricity to extend the vehicle's range. EREVs can operate in all-
electric mode for shorter trips, but the generator allows them to travel further than traditional
battery-electric vehicles (BEVs).
1.4 Neighborhood Electric Vehicles (NEVs)

These are small electric vehicles designed for short trips in urban or suburban areas.
They typically have a top speed of 25 mph and a range of up to 50 miles on a single charge.
Electric Buses and Trucks: These are electric vehicles designed for public
transportation and commercial use. Electric buses and trucks can have a range of up to 300
miles on a single charge and are becoming increasingly popular as a more sustainable
alternative to diesel-powered vehicles.
Overall, electric vehicles are becoming increasingly popular as a more sustainable and
environmentally friendly alternative to traditional gasoline-powered vehicles. As
advancements in battery technology continue to improve, it is likely that the variety and
availability of electric vehicles will continue to increase in the years to come.
1.5 Main Components of Electric Vehicle:

1) Battery: The battery is the heart of an EV, providing power to the electric motor. EV
batteries are typically made of lithium-ion cells and are rechargeable.
2) Electric motor: The electric motor converts electrical energy from the battery into
mechanical energy to power the wheels. There are two main types of electric motors used in
EVs: AC induction motors and permanent magnet motors.
3) Power electronics: The power electronics in an EV control the flow of electricity
between the battery and the electric motor. They include components such as the inverter,
converter, and charger.
4) Onboard charger: The onboard charger is responsible for converting AC power from an
external source (such as a charging station) into DC power to charge the battery.

Introduction
5) DC-DC converter: The DC-DC converter is responsible for converting the high-voltage
DC power from the battery to the lower-voltage DC power needed to run accessories such as
the radio and air conditioning.
6) Thermal management system: The thermal management system regulates the
temperature of the battery and electric motor to ensure optimal performance and longevity.
7) Regenerative energy system: Regenerative energy system is a system that captures
energy that would otherwise be lost during vehicle is in downward slope motion and uses it
to recharge the battery.
8) Vehicle control unit: The vehicle control unit (VCU) is the brain of the EV, controlling
various functions such as the motor, brakes, and battery management system. It also
communicates with the driver through the dashboard display.
1.5.1 Battery:
Batteries are one of the most critical components of an electric vehicle (EV). They are
responsible for storing the electrical energy that powers the electric motor. The performance
of an EV battery depends on factors such as its chemistry, capacity, and charging rate.
Lithium-ion batteries are the most common type of battery used in EVs due to their high
energy density, long cycle life, and relatively low weight. These batteries consist of multiple
cells that are connected in series and parallel to achieve the desired voltage and capacity.
The range of an EV depends largely on the capacity of its battery, which is measured
in kilowatt-hours (kWh). Higher-capacity batteries can store more energy and provide
longer range, but they also increase the weight and cost of the vehicle. Charging an EV
battery can be done using a standard household outlet, but it is slow and may take several
hours to fully charge.
Fast-charging stations, on the other hand, can charge an EV battery to 80% in less than
an hour, but they are currently less common and may require special adapters. The lifespan
of an EV battery depends on several factors, including its chemistry, usage pattern, and
operating temperature. In general, EV batteries are designed to last for several years and
may have a warranty of 8 to 10 years or more. At the end of its life, an EV battery can be
recycled or repurposed for other applications.

Introduction
Fig.1.5.1 Battery
1.5.2 Electric Motor:

Electric motors come in many different types, sizes, and configurations, depending on
the application. The most common type of electric motor used today is the AC induction
motor, which is used in everything from household appliances to industrial equipment.
Another common type of electric motor is the permanent magnet motor, which is often used
in electric vehicles due to its high efficiency and power density.
Electric motors have several advantages over other types of power sources, including
high efficiency, low maintenance, and quiet operation. They are also highly controllable,
allowing for precise speed and torque control, which is important in many applications.
However, electric motors also have some limitations, including the need for a power source
and the potential for overheating if operated at high temperatures for extended periods of
time.
Electric motors have become a vital component of modern technology, powering

everything from electric cars to wind turbines to robotics. Their versatility and efficiency
make them an important part of the transition to a more sustainable, low-carbon energy
system.

Introduction
1.5.2.1 Types of Electric Motors:
There are several types of electric motors used in electric vehicles (EVs), each with its
own unique characteristics and advantages. The most common types are:
1)Permanent magnet synchronous motor (PMSM): This type of motor uses permanent
magnets in the rotor to generate a magnetic field that interacts with the stator to produce
rotational motion. PMSMs are highly efficient and have high power density, making them a
popular choice for EVs.
2)Induction motor (IM): Also known as asynchronous motors, these motors use
electromagnetic induction to produce rotational motion. IMs are relatively inexpensive and
have a simple design, but they have lower efficiency than PMSMs and require more
maintenance.
3)Switched reluctance motor (SRM): These motors use the magnetic reluctance of the
rotor to produce rotational motion. They are highly efficient, but they have a more complex
control system than other types of motors.
4)Brushless DC motor (BLDC): BLDC motors use electronic commutation to control the
rotation of the motor. They are highly efficient and have a long lifespan, but they can be
more expensive than other types of motors.
The choice of motor type depends on several factors, including the vehicle's
performance requirements, cost, and efficiency. Many EVs use a combination of motor
types, such as a PMSM for high-speed operation and an IM for low-speed operation.
Overall, the use of electric motors in EVs has revolutionized the automotive industry and
has helped to pave the way for a more sustainable, low-carbon future.
1.5.2.2 Permanent Magnet Synchronous Motor:
A permanent magnet synchronous motor (PMSM) is a type of electric motor that uses
permanent magnets in the rotor to create a magnetic field that interacts with the stator's
magnetic field to produce rotational motion. PMSMs are highly efficient, with efficiency
levels of up to 98%, and have a high power density, making them a popular choice for a

Introduction
wide range of applications, including electric vehicles (EVs).PMSMs have several

advantages over other types of electric motors, including their high efficiency, low
maintenance, and excellent controllability. They are also highly reliable and have a long
lifespan, making them a cost-effective choice in the long run.In EVs, PMSMs are commonly
used in the traction motor, which powers the wheels of the vehicle. PMSMs provide high
torque at low speeds, which is important for starting and accelerating the vehicle, and can
operate at high speeds without sacrificing efficiency, which is important for maintaining
high speeds on highways. Overall, PMSMs are a highly efficient and reliable type of electric
motor that is widely used in a variety of applications, including EVs. Their excellent
performance and controllability make them an essential component in the transition to a
more sustainable, low-carbon energy system.
Fig.1.5.2 Permanent Magnet Synchronous Motor
1.5.2.3 Induction Motor:
An induction motor is a type of electric motor that uses electromagnetic induction to

produce rotational motion. It operates by applying an alternating current (AC) to the stator

Introduction
windings, which creates a rotating magnetic field. This field induces a current in the rotor
windings, which then produces a second magnetic field that interacts with the stator field to
create rotational motion. Induction motors are widely used in many applications, including
industrial machinery, household appliances, and electric vehicles. They are relatively
inexpensive and have a simple design, which makes them a popular choice for many
applications.
One of the main advantages of induction motors is their reliability, as they have no
brushes or commutators that can wear out or require maintenance. They also have a high
starting torque, which makes them well-suited for applications that require high torque at
low speeds .However, induction motors also have some limitations, including lower
efficiency compared to other types of electric motors, such as permanent magnet motors.
They also require a power source with a specific frequency to operate, which can limit their
use in some applications. Despite their limitations, induction motors are still widely used in
many applications due to their reliability and low cost. They are an essential component of
many industries and have helped to drive technological advancements over the past century.
Fig.1.5.3 Induction Motor
1.5.2.4 Switched Reluctance Motor:
A switched reluctance motor (SRM) is a type of electric motor that operates based on
the principle of magnetic reluctance. It is similar in design to a reluctance motor but has a
more complex control system that allows for more precise control of the motor's operation.

Introduction
SRMs have a rotor made up of iron poles that are attracted to the stator's magnetic field. The
stator is designed with windings that are energized in a sequence, creating a magnetic field
that attracts the rotor poles. The rotor then aligns with the stator poles and continues to rotate
as the stator windings are sequentially energized and de-energized. SRMs have several
advantages over other types of electric motors, including high efficiency, high torque
density, and low cost. They also do not require permanent magnets, which can be expensive
and difficult to source. One of the main disadvantages of SRMs is their complex control
system, which requires precise timing and sequencing of the stator windings. This can make
them more difficult to design and manufacture than other types of electric motors. Despite
their limitations, SRMs are well-suited for many applications, including industrial
machinery, aerospace, and electric vehicles. They offer high efficiency and torque density,
which can help to reduce the size and weight of the motor. As technology continues to
advance, it is likely that SRMs will become more widespread in many industries due to their
unique combination of performance and affordability.
Fig.1.5.4 Switched Reluctance Motor

Introduction
1.5.2.5 Brushless DC Motor:
A brushless DC motor (BLDC) is a type of electric motor that operates using direct
current (DC) power and does not require the use of brushes to transfer power to the rotating
shaft. Instead, a BLDC motor uses a system of permanent magnets and electronically
controlled switching circuits to transfer power to the rotor, resulting in a more efficient and
reliable motor than traditional brushed motors. BLDC motors are popular in a wide range of
applications, including electric vehicles, industrial machinery, robotics, and consumer
electronics, due to their high efficiency, low noise and vibration, and increased control and
accuracy. Compared to traditional brushed motors, BLDC motors have a longer lifespan,
require less maintenance, and offer greater control over motor speed and torque. The basic
design of a BLDC motor consists of a rotor with permanent magnets and a stator with a
series of electromagnets that are controlled by an electronic controller. As the rotor rotates,
the magnetic field of the permanent magnets interacts with the magnetic field of the stator
electromagnets, causing the rotor to turn. The electronic controller monitors the position of
the rotor and adjusts the current to the stator electromagnets to maintain the desired speed
and torque. There are several advantages to using a BLDC motor over a traditional brushed
motor. One of the main advantages is increased efficiency. BLDC motors have a higher
power-to-weight ratio and can achieve up to 95% efficiency, compared to brushed motors
which typically have efficiencies around 75-80%. This increased efficiency means that less
energy is wasted as heat, resulting in lower operating costs and longer lifespan. Another
advantage of BLDC motors is their reduced noise and vibration. Because they do not use
brushes, there is no contact between the rotor and stator, resulting in a smoother operation
and less noise and vibration. This makes BLDC motors ideal for applications where noise
and vibration are a concern, such as in medical equipment or consumer electronics. BLDC
motors also offer greater control and accuracy over motor speed and torque. The electronic
controller can monitor the position of the rotor and adjust the current to the stator
electromagnets to maintain the desired speed and torque, resulting in more precise control
over the motor's operation. This makes BLDC motors ideal for applications where precise
control is required, such as in robotics or automation. Despite their many advantages, there
are some challenges associated with using BLDC motors. One of the main challenges is the
complexity of the electronic control system. The electronic controller must be able to

Introduction
monitor the position of the rotor and adjust the current to the stator electromagnets in real-
time, which can be a complex and costly process. Another challenge is the cost of the motor
itself. BLDC motors are typically more expensive than brushed motors, which can make
them less attractive for some applications where cost is a primary concern. However, the
increased efficiency and longer lifespan of BLDC motors can often offset the higher initial
cost over the life of the motor. In conclusion, BLDC motors offer many advantages over
traditional brushed motors, including higher efficiency, reduced noise and vibration, and
greater control and accuracy over motor speed and torque. While there are some challenges
associated with using BLDC motors, their superior performance makes them a popular
choice in many applications where reliability and efficiency are critical.
Fig.1.5.5 Brushless DC Motor
1.5.3 Power Electronics:
Power electronics play a crucial role in electric vehicles (EVs) as they are responsible
for controlling the flow of electrical power from the battery to the motor and other auxiliary
systems. Power electronics devices such as inverters, DC-DC converters, and on-board
chargers are used in EVs to efficiently convert and manage electrical energy.

Introduction
Inverters convert the DC power from the battery to AC power for the electric motor,
while DC-DC converters step down the high-voltage battery power to a lower voltage to
power auxiliary systems such as the air conditioning and lighting. On-board chargers
convert AC power from a charging station to DC power to recharge the battery.
Efficient power electronics are critical for extending the range of an EV, reducing
energy consumption, and improving the overall performance of the vehicle. As the demand
for EVs continues to grow, advancements in power electronics technology will be necessary
to improve their efficiency and reduce their cost.
1.5.4 ON Board Charger :
An on-board charger is a device installed in an electric vehicle (EV) that is responsible

for converting AC power from a charging station into DC power to recharge the EV's
battery. The on-board charger manages the charging process and ensures that the battery is
charged safely and efficiently.
On-board chargers are typically built into the EV and can accept different input
voltages and power levels. They can also support different charging protocols, such as AC
Level 1, AC Level 2, and DC fast charging.
AC Level 1 charging uses a standard 120-volt household outlet and provides a slow
charge rate, while AC Level 2 charging uses a 240-volt charging station and provides a
faster charge rate.
DC fast charging provides an even faster charging rate by using high-power DC

electricity. On-board chargers play a critical role in the adoption of EVs by providing a
convenient and reliable way to recharge the vehicle's battery.
The efficiency and speed of the charging process are essential factors in determining
the practicality of EVs for daily use, making on-board chargers an essential component of
EV technology.

Introduction
Fig.1.5.6 On Board Charger
1.5.5 Dc to Dc Converter:
A DC-DC converter is an electronic device used in electric vehicles (EVs) to convert

high-voltage DC power from the battery to a lower voltage level suitable for powering
auxiliary systems such as the air conditioning, lighting, and audio systems.
The DC-DC converters are designed to be efficient and lightweight, as they are
typically installed in the EV and draw power from the battery. They can accept a wide range
of input voltage and provide a stable output voltage regardless of variations in the input
voltage or load. DC-DC converters play a crucial role in EVs as they allow the use of a
single battery pack to power both the main electric motor and the auxiliary systems,
reducing the weight and complexity of the vehicle. Additionally, they can help to extend the
range of an EV by minimizing the amount of energy consumed by the auxiliary systems.The
DC-DC converters are an essential component of EV power electronics, enabling the
efficient and reliable use of high-voltage DC power from the battery to power the various
systems in an EV.
Fig.1.5.7 Dc to Dc Converter

Introduction
1.5.6 Thermal Management System:
Thermal management systems (TMS) are critical components of electric two-wheelers

(E2Ws) as they help to maintain optimal operating temperatures for the battery and motor.
The TMS in E2Ws typically include a combination of air-cooling and liquid-cooling
systems.
Air-cooling systems are usually simple and inexpensive, but they are not very effective
at dissipating heat. Liquid-cooling systems are more efficient and can dissipate more heat,
but they are more complex and expensive. The TMS help to regulate the temperature of the
battery and motor, which is crucial for their performance and longevity. High temperatures
can degrade the battery and motor components, reducing their efficiency and lifespan.
On the other hand, low temperatures can reduce the battery's capacity and
performance. The TMS also help to manage the thermal loads during rapid charging, which
can generate a lot of heat and cause thermal runaway if not properly managed. By regulating
the temperature during charging, the TMS can help to extend the battery's lifespan and
ensure safe operation. Overall, the TMS is a critical component of E2W technology,
ensuring optimal thermal management for the battery and motor, improving their
performance, and extending their lifespan.
1.5.7 Regenerative Energy System:
Regenerative energy systems are a type of energy system used in electric vehicles
(EVs) that can capture and store energy that would otherwise be lost during braking and
deceleration. When an EV brakes or decelerates, the kinetic energy is converted into
electrical energy and stored in the battery using a regenerative braking system. This energy
can then be used to power the vehicle's electric motor and reduce the load on the battery.
Regenerative energy systems are an important feature of EV technology as they can

significantly improve the vehicle's energy efficiency and range. By capturing energy that
would otherwise be wasted, regenerative energy systems can reduce the energy consumption
of the vehicle and extend the range of the battery.

Introduction
Regenerative energy systems are also environmentally friendly, as they reduce the
need for traditional braking systems that generate heat and wear down the brake pads,
leading to increased emissions and waste.Regenerative energy systems are an essential
component of EV technology, helping to improve energy efficiency, reduce emissions, and
extend the range of the vehicle.
Fig.1.5.8 Regenerative Energy System

1.5.8 Electric Control Unit:
An Electric Control Unit (ECU) is a crucial component of electric two-wheelers
(E2Ws) as it is responsible for controlling and regulating the vehicle's electrical system,
including the motor, battery, and other auxiliary systems. The ECU is essentially the brain of
the E2W, as it receives information from various sensors and sends commands to the various
electrical components to ensure smooth and efficient operation. The ECU is responsible for
managing the vehicle's performance, including acceleration, speed, and torque, and ensuring
the safety and reliability of the electrical system.
The ECU in E2Ws is typically a sophisticated computer system with advanced
algorithms and software programs that monitor and control the various electrical
components. The ECU can also communicate with other electronic systems in the vehicle,
such as the charging system, display panel, and navigation system.

Introduction
The ECU plays a critical role in optimizing the energy efficiency and range of the
E2W. By controlling the motor and battery, the ECU can minimize energy consumption and
extend the range of the vehicle. Additionally, the ECU can monitor the battery's health and
performance and optimize the charging process to maximize its lifespan. Overall, the ECU is
a critical component of E2W technology, ensuring optimal control and regulation of the
electrical system and improving the vehicle's performance, energy efficiency, and reliability.
Fig.1.5.9 Vehicle Control Unit
1.6 Working of Electric Vehicle:

Electric two-wheelers, like traditional gasoline-powered two-wheelers, have two
wheels, a frame, a seat, handlebars, brakes, and a suspension system. However, the main
difference is that an electric two-wheeler is powered by an electric motor and a battery pack,
rather than an internal combustion engine.
The electric motor, which is typically located at the rear wheel hub, is powered by a
lithium-ion battery pack that is usually located under the seat or in a compartment under the
rider's feet. The battery pack is charged by plugging the vehicle into a wall socket or a
dedicated charging station. When the rider twists the throttle, the electric motor receives a
signal from the controller to start spinning the rear wheel. The controller regulates the flow
of electricity from the battery to the motor, allowing the rider to control the speed and
acceleration of the vehicle.

Introduction
Electric two-wheelers also have regenerative braking systems that convert kinetic
energy into electrical energy when the rider applies the brakes. This energy is then stored
back into the battery pack, increasing the vehicle's range. Overall, electric two-wheelers are
quiet, efficient, and produce zero emissions, making them an eco-friendly alternative to
traditional gasoline-powered two-wheelers. BEVs are fully electric vehicles that run solely
on battery power and need to be plugged in to charge. PHEVs have both an electric motor
and a gasoline engine, which can be charged from an external power source and can also use
the gasoline engine as a backup. HEVs have both an electric motor and a gasoline engine,
but the electric motor is not designed to be charged from an external source and instead, the
battery is charged through regenerative braking and the gasoline engine.
Electric vehicles have several advantages over traditional gasoline-powered vehicles,
such as producing zero emissions, lower operating costs, and being quieter and smoother to
drive. However, they also have some disadvantages, such as a higher upfront cost and longer
charging times. Overall, electric vehicles are becoming more popular as technology
improves and charging infrastructure becomes more widespread, leading to a reduction in
carbon emissions and a cleaner environment.

Chapter –2
Literature Review
Literature Review
________________________________________________________________________________
Chapter-2 LITERATURE REVIEW
_____________________________________________________________
2.1 Review of papers
[1] EVs.Rahul B. Gupta designed and developed the electric two-wheeler in his article he
explained various aspects of electric vehicles which include the design of the frame, battery
specification, and their components.
[2] K.W. Cheng wrote an article based on recent developments in electric vehicles that
include fast charging and braking and power generation
[3] Suchismita Nayak studied the status of electric vehicle charging methods. This article
gives a brief overview of present methods recommended for EV charging.
[4] Hemavathi and A shisha have studied the current and future trends in ev battery charging
methodologies.
[5]In 2017, Liu et al. proposed a self-charging electric vehicle system that uses a
thermoelectric generator (TEG) to convert waste heat from the vehicle's engine into
electricity. The TEG was mounted on the exhaust manifold of the engine, and the generated
electricity was used to charge the vehicle's battery. The authors reported that their system
could improve the fuel economy of the vehicle by up to 5%..
[6] In 2020, Zhang et al. developed a self-charging electric vehicle system that used a
combination of solar panels and wireless power transfer. The vehicle was equipped with a
large solar panel on the roof, which provided a constant source of energy during the day. At
night, the vehicle could be charged wirelessly using a charging pad installed in the owner's
garage. The authors reported that their system could provide a range of up to 150 km on a
single charge.
[7] One of the earliest studies on self-charging EVs was conducted by Bao et al. (2013), who
proposed a wireless power transfer system that would allow EVs to charge while driving.
The system consisted of a series of coils embedded in the road, which would generate a
magnetic field that could be picked up by a coil mounted underneath the vehicle. The
authors demonstrated that their system could provide a charging efficiency of up to 90% at
speeds of up to 100 km/h.
Dept of Mech. Engg ; VIIT ;Visakhapatnam Page 20

Literature Review
[8] Wang et al. (2019) developed a self-charging EV that used a hybrid energy storage
system consisting of both supercapacitors and lithium-ion batteries. The system was able to
store energy from both regenerative braking and solar panels mounted on the vehicle, which
could then be used to power the vehicle's electric motor. The authors reported that their
system was able to achieve an energy efficiency of over 80% and a range of up to 80 km on
a single charge.
[9] Another interesting approach to self-charging EVs was proposed by Peng et al. (2020),
who developed a system that could generate electricity from the movement of the vehicle
itself. The system consisted of a series of piezoelectric generators embedded in the road,
which would generate electricity when compressed by the weight of passing vehicles. The
authors reported that their system could generate up to 3 kW of power per kilometer of road,
which could be used to power EVs as they drove.
[10] Zhou et al. (2021) proposed a self-charging EV system that used a wireless power
transfer system similar to that proposed by Bao et al. (2013), but with the addition of a
supercapacitor-based energy storage system. The authors demonstrated that their system
could provide a charging efficiency of up to 95%, allowing the vehicle to be charged while
parked or even while driving on roads equipped with wireless charging coils.
[11] In a 2021 study, Wang et al. proposed a self-charging electric vehicle system that uses a
combination of solar panels, regenerative braking, and a supercapacitor-based energy
storage system. The system was able to capture and store energy from both solar panels and
regenerative braking, which could then be used to power the vehicle's electric motor. The
authors reported that their system could provide a range of up to 70 km on a single charge.
2.2 The Knowledge gap in earlier investigations

The extensive literature survey presented above reveals the following knowledge gap
in the research reported so far:
 There are still technical and logistical challenges that need to be addressed, such as
the cost of implementing charging infrastructure and the need for standardization, the
development of self-charging EVs represents an important step towards a sustainable
transportation future.
Dept of Mech Engg,VIIT,Visakhapatnam Page 21

Literature Review
 Although, a great deal of work has been done on the different modes of charging
modes in Electric Vehicle,
 Although a number of research efforts have been devoted to study about the different
types of charging modes, however the study on self charging of the vehicle is hardly
been reported in the literature.
 Studies carried out worldwide to reduce the charging time of an electric vehicle but
there are certain limitations acts accordingly.
2.3 Objectives of the present work

The knowledge gap in the existing literature summarized above has helped to set the
objectives of this research work which are outlined as follows:
 To overcome the major limitations of current Electric vehicles.
 To increase the efficiency of the vehicles also satisfies the user's economical
factor.
 To reduce the recharging time for vehicle by means of self charging.
Dept of Mech Engg,VIIT,Visakhapatnam Page 22

Chapter –3
Methodologies
Methodology
_________________________________________________________________________
Chapter-3 METHODOLOGY
_______________________________________________________________
3.1 Methodology(Experimentation)
This chapter presents the materials and methods used for the fabrication of wind
turbine blade. It presents the design and manufacturing of wind turbine blade and the
information about the analysis of the blade.
3.2 Wind Turbine Blade:
Wind turbine blades play a crucial role in generating electricity from wind energy. The
blades are responsible for converting the kinetic energy of the wind into mechanical energy,
which can then be used to generate electricity.
They consist of a tower, blades, and a generator. The tower supports the blades, which
rotate when the wind blows. The kinetic energy from the blades is then converted into
electrical energy by the generator. There are two types of wind turbines: horizontal-axis
wind turbines (HAWTs) and vertical-axis wind turbines (VAWTs). HAWTs are the most
common and have a horizontal axis of rotation, while VAWTs have a vertical axis of
rotation. HAWTs are typically more efficient, but VAWTs can be better suited for urban
areas or locations with changing wind directions. Wind turbines are a renewable energy
source and are becoming increasingly popular to generate electricity. They are also
relatively low maintenance and have a long lifespan. However, their installation can be
expensive, and they can be noisy. Overall, wind turbines are an important part of the
transition to cleaner energy sources and can help reduce our reliance on fossil fuels.
In wind turbines, the blade design needs to be aerodynamically efficient to capture
maximum wind energy and convert it into electricity. In gas turbines, the blade design needs
to withstand high temperatures and stresses while efficiently converting fuel energy into
mechanical power. In propellers, the blade design needs to generate enough thrust while
minimizing noise and vibration. Blade design requires careful consideration of various
factors, and the design process often involves a combination of computer simulations,
experimental testing, and optimization techniques. Advanced materials, such as composites,
are also being developed to improve the efficiency, durability, and performance of blades.
Dept of Mech.Engg, VIIT, Visakhapatnam Page 23

Methodology
Wind turbine blades are an essential component of wind turbines that convert the
kinetic energy of wind into electrical energy. The design of wind turbine blades is critical to
the performance and efficiency of the wind turbine. The primary considerations in the
design of wind turbine blades are aerodynamics, structural integrity, and manufacturability.
Aerodynamically, the blade's shape is designed to extract the maximum amount of energy
from the wind while minimizing drag and noise. The blade's shape is typically airfoil-
shaped, similar to an airplane wing, with a curved surface on the top and a flat surface on the
bottom. The angle of the blade's twist, or the angle between the blade's root and tip, is also
crucial in optimizing the blade's performance. Structurally, the blade's design must be robust
enough to withstand the harsh conditions of wind energy production, including high winds,
fatigue, and lightning strikes. The blade's materials and construction must be carefully
chosen to ensure the blade's strength and durability over its lifetime. Finally, the
manufacturability of the blade is essential to ensure its cost-effectiveness. The blade's design
must be optimized for efficient and low-cost manufacturing processes, such as automated
composite layup or injection molding. Overall, the design of wind turbine blades is a
complex and iterative process that involves considering multiple factors to achieve the best
possible performance and efficiency.
3.2.1 Design of wind turbine blade:
Fig.3.1 Design of Blade

Methodology
The length of the blade directly impacts the amount of energy that can be extracted
from the wind. Longer blades can capture more wind energy, but they also require more
material and can be more difficult to manufacture.
The twist angle of the blade refers to the angle between the root and the tip of the blade. A
blade with a twist angle can optimize the angle of attack of the blade at different points
along its length.
3.3 Materials used for the turbine blade:
Table 3.3.1 Mechanical Properties of PLA and PEEK Material:
3.3.2 PLA Material

Polylactic Acid (PLA) is a biodegradable and biocompatible thermoplastic polymer that is
widely used in 3D printing. PLA is derived from renewable resources such as corn starch,
sugarcane, or tapioca roots, making it an environmentally friendly alternative to traditional
petroleum-based plastics.
PLA has been gaining popularity as a material for printing wind turbine blades due to its
high strength-to-weight ratio, stiffness, and low coefficient of thermal expansion. These
properties make it an ideal material for producing large, lightweight structures that can
withstand high wind speeds and temperatures.

Methodology
The manufacturing process for PLA wind turbine blades involves printing individual
sections of the blade using a 3D printer and then assembling them to form the complete
blade. The resulting blade is lightweight, durable, and easy to install, making it an ideal
choice for small wind turbines used in residential and commercial applications.
One of the main advantages of using PLA for wind turbine blades is its biodegradability. At
the end of their life cycle, PLA blades can be easily decomposed in industrial composting
facilities, reducing waste and environmental impact. Moreover, PLA is a safe and non-toxic
material that poses no harm to humans or the environment.
However, PLA has some limitations that need to be considered when using it for wind
turbine blades. For instance, it is sensitive to high temperatures, which can causedeformation
and reduce its mechanical properties. Therefore, PLA blades are not recommended for use in
high-temperature environments such as industrial wind turbines.
Fig.3.3 Blade printed with PLA Material

In conclusion, PLA is a promising material for producing wind turbine blades due to its
biodegradability, high strength-to-weight ratio, and low coefficient of thermal expansion.
With ongoing advancements in 3D printing technology and material science, PLA could
become an even more attractive option for sustainable wind energy production in the future.
It is not suitable for wind turbines which run at high speed, after inserting it to the
motor the strength reduces and brakes when the vehicle reaches above 40kmph.
Young’s modulus: - 3.5*10^9 Pa
Poison ratio: 0.27

Methodology
Density: 1300 Kg/m^3

Yield strength: 50Mpa
3.3.3 PEEK Material
Polyether Ether Ketone (PEEK) is a high-performance thermoplastic polymer that is
increasingly being used in additive manufacturing for various applications, including wind
turbine blades. PEEK has exceptional mechanical and thermal properties, making it an ideal
material for producing lightweight and durable wind turbine blades.
PEEK is a semi-crystalline polymer with excellent resistance to chemicals, high
temperatures, and wear, making it suitable for use in harsh environments. The material's
stiffness, strength, and low coefficient of thermal expansion make it a good option for
producing blades that can withstand high wind speeds and temperatures.
The manufacturing process for PEEK wind turbine blades involves 3D printing individual
sections of the blade using a high-temperature 3D printer and then assembling them to form
the complete blade. The resulting blade is lightweight, durable, and can withstand harsh
environmental conditions. One of the main advantages of using PEEK for wind turbine
blades is its exceptional mechanical properties. PEEK has a high strength-to-weight ratio,
making it an ideal material for producing lightweight structures that can withstand high
loads and vibrations. Additionally, PEEK's low coefficient of friction and excellent wear
resistance make it a good option for reducing maintenance and repair costs.
Moreover, PEEK is a thermoplastic polymer that is easy to process, making it an attractive
option for manufacturers looking to produce complex shapes and geometries. The material is
also recyclable and can be reused, reducing waste and environmental impact.
However, PEEK is an expensive material, which can increase the overall cost of producing
wind turbine blades. Additionally, it requires a high-temperature 3D printer, which can also
add to the manufacturing costs.
In conclusion, PEEK is a high-performance material that offers exceptional
mechanical and thermal properties, making it an ideal option for producing wind turbine
blades. Despite its high cost, PEEK's excellent durability and low maintenance requirements
make it a good long-term investment for wind energy producers.
Young’s modulus: - 7.85*10^9 Pa
Poison ratio: 0.3779

Methodology
Density: 1325 Kg/m^3

Yield strength: 70Mpa
3.4 Factors in consideration of wind blade design:
The design of wind turbine blades is a complex process that involves considering
multiple factors to achieve optimal performance, efficiency, and durability. Here are some of
the key factors that are typically taken into consideration in the design of wind turbine
blades:
 Aerodynamics: The shape and angle of the blade's twist must be optimized to extract
the maximum amount of energy from the wind while minimizing drag and noise.
 Structural integrity: The blade's design must be robust enough to withstand the harsh
conditions of wind energy production, including high winds, fatigue, and lightning
strikes.
 Materials and construction techniques must be carefully chosen to ensure the blade's
strength and durability over its lifetime.
 Weight: The weight of the blade must be carefully controlled to ensure that the blade
can be mounted on the rotor hub and rotate efficiently in low wind speeds.
 Cost-effectiveness: The design must be optimized for efficient and low-cost
manufacturing processes, such as automated composite layup or injection molding.
 Environmental impact: The blade's design must take into consideration the
environmental impact of the manufacturing process, transportation, installation, and
disposal.
 Noise: The design must minimize noise to reduce the impact on nearby communities.
The design of wind turbine blades requires careful consideration of multiple factors to
ensure optimal performance and efficiency while minimizing environmental impact and
cost.
3.5 Design Parameters of Blade in Kinematic Calculator:
3.5.1 Airfoil Structure: The NACA 4412 airfoil is a widely used airfoil shape that was
designed by the National Advisory Committee for Aeronautics (NACA) in the 1940s. This
airfoil has a thickness of 12% of its chord length and a camber line that is symmetric about

Methodology
its chord. The NACA 4412 airfoil is commonly used in various applications, including wind
turbines, aircraft, and hydrofoils.
The NACA 4412 airfoil is well suited for applications where a balance of lift and drag is
required. Its thickness provides good structural support, while its symmetric camber line
provides a predictable lift and drag behavior. The NACA 4412 airfoil has low drag
characteristics at moderate to high angles of attack, making it useful in applications where
high lift is required. The NACA 4412 airfoil has been extensively studied and tested, and its
performance characteristics are well documented. It has become a standard reference for
airfoil design, and many other airfoils have been derived from its basic geometry.
Fig:3.5.1 Kinematic Calculator

The NACA 4412 airfoil is a well-known and widely used airfoil shape that provides good
lift and drag characteristics, making it suitable for various applications.
Fig:3.5.2 NACA 4412 AIRFOIL

Methodology
3.5.2 Alpha Angle: The alpha angle is a critical parameter in the design of wind turbine
blades. It refers to the angle between the chord line of the blade and the direction of the
wind. The angle of attack affects the amount of lift and drag generated by the blade, which
in turn affects the blade's overall performance and efficiency. In wind turbine blade design,
the alpha angle is typically optimized to achieve the best possible performance. A small
positive angle of attack can increase the lift generated by the blade, while a negative angle of
attack can increase drag. However, if the angle of attack is too large, the blade can stall,
reducing its lift and increasing drag.
The alpha angle is also important in determining the optimal twist angle of the blade. The
twist angle refers to the change in the angle of attack along the length of the blade. By
adjusting the twist angle, the designer can control the distribution of lift along the blade's
length, optimizing performance and efficiency.
Overall, the alpha angle is a crucial parameter in the design of wind turbine blades. It must
be carefully considered and optimized to achieve the best possible performance and
efficiency while avoiding stall and excessive drag.
3.5.3 Coefficient of Lift & Coefficient of Drag: The coefficient of lift is a dimensionless
value that represents the lift generated by an object, such as an airfoil or a wing, relative to
its size, shape, and orientation. It is defined as the ratio of the lift force acting on the object
to the dynamic pressure of the fluid flow around it and the reference area of the object.The
coefficient of lift is an essential parameter in aerodynamics, as it determines the ability of an
object to generate lift and control its flight. It varies with the angle of attack, airspeed, and
other factors that affect the flow of the fluid around the object. By analyzing the coefficient
of lift, engineers can design and optimize the performance of various aerodynamic systems,
such as aircraft, wind turbines, and racing cars. As well as The coefficient of drag is a
dimensionless value that represents the resistance to motion of an object through a fluid,
such as air or water. It is defined as the ratio of the drag force acting on the object to the
dynamic pressure of the fluid flow around it and the reference area of the object.
The coefficient of drag is an important parameter in aerodynamics and fluid mechanics, as it
determines the amount of energy required to overcome the resistance of an object in motion
through a fluid. It varies with the shape, size, and orientation of the object, as well as the
properties of the fluid flow, such as viscosity and density. By analyzing the coefficient of

Methodology
drag, engineers can design and optimize the performance of various systems, such as
vehicles, ships, and buildings, to minimize their energy consumption and improve their
efficiency. If coefficient of lift is high then it will be able to carry heavy loads. If coefficient
of drag is low then the speed will be high.
3.5.4 Airfoil Parameters:
A. Kinematic Turbine Power Velocity Graph
B. Chord Length vs Radius of Rotor Graph
C. Twist angle vs Radius of Rotor Graph
a) Kinematic Turbine Power Velocity Graph:
Fig:3.5.3 Kinetic Turbine Power Velocity Graph

The velocity of fluid vs power of turbine graph is a representation of the relationship
between the velocity of air flow and the power output of a turbine. The graph typically
shows that as the velocity of air flow increases, the power output of the turbine also
increases until it reaches a maximum value. The graph is important in the design and
optimization of various hydrodynamic systems, such as turbines, and generators, as it helps
engineers to understand the performance characteristics of these systems under different
operating conditions. By analyzing the graph, engineers can determine the optimal velocity
of air flow to achieve maximum power output from the turbine while minimizing energy
losses due to drag and turbulence. The shape of the velocity of fluid vs power of turbine
graph depends on several factors, such as the design of the turbine, the properties of the air
flow, and the operating conditions of the system. In general, turbines are designed to

Methodology
operate at a specific range of air velocities, and the graph can help to determine the ideal
operating conditions for maximum efficiency and power output.
b) Chord Length Vs Radius of rotor Graph
Fig:3.5.4 Chord Length vs Radius Graph

The chord length of a wind turbine vs radius of rotor graph is a representation of the
relationship between the chord length of the wind turbine blade and the radius of the rotor.
The graph typically shows that as the radius of the rotor increases, the chord length of the
blade also increases until it reaches a maximum value. The graph is important in the design
and optimization of wind turbines as it helps engineers to understand the performance
characteristics of the blade under different operating conditions. By analyzing the graph,
engineers can determine the optimal chord length for the blade to achieve maximum power
output while minimizing structural loads and noise emissions. The shape of the chord
length of a wind turbine vs radius of rotor graph depends on several factors, such as the
aerodynamic design of the blade, the properties of the wind flow, and the operating
conditions of the wind turbine. In general, wind turbine blades are designed to operate at a
specific range of rotor radii, and the graph can help to determine the ideal chord length for
maximum efficiency and power output.

Methodology
Overall, the chord length of a wind turbine vs radius of rotor graph is a useful tool in the
design and optimization of wind turbines, helping to ensure that they are operating at their
highest potential while minimizing the impact on the environment.
c) Twist Angle VS Radius of Rotor Graph:
Fig:3.5.5 Twist Angle vs Radius Graph

The twist angle of a wind turbine vs radius of rotor graph is a representation of the
relationship between the twist angle of the wind turbine blade and the radius of the rotor.
The graph typically shows that as the radius of the rotor increases, the twist angle of the
blade also increases until it reaches a maximum value. The twist angle of the wind turbine
blade is an important parameter in the design and optimization of wind turbines as it
determines the angle of attack of the blade and its ability to efficiently capture the kinetic
energy of the wind. By analyzing the twist angle of the blade at different radii, engineers
can optimize the performance of the wind turbine to achieve maximum power output while
minimizing loads and noise emissions.
The shape of the twist angle of a wind turbine vs radius of rotor graph depends on several
factors, such as the aerodynamic design of the blade, the properties of the wind flow, and
the operating conditions of the wind turbine. In general, wind turbine blades are designed
to operate at a specific range of twist angles, and the graph can help to determine the ideal
twist angle for maximum efficiency and power output. Overall, the twist angle of a wind

Methodology
turbine vs radius of rotor graph is a valuable tool in the design and optimization of wind
turbines, helping to ensure that they are operating at their highest potential while
minimizing their impact on the environment.
3.6 Detailed Flow Chart of Working:
Fig.3.6: Flowchart of working
When the vehicle is in motion there is a presence of air resistance which is used to
rotate the dc motor which is in the form of a wind turbine. When the turbine rotates there is
the generation of voltage as well as current so with the help of a buck-boost converter
keeping the current constant which is 2.08amps and nearly 48v volts are generated from this
dc motor. So these will be used to charge the battery. There will be the presence of two
batteries the vehicle runs with the run of 1 battery and another battery gets charged with the
help of a wind source. This will happen when the vehicle is in motion. When the vehicle is
in rest position the vehicle will be charged with the help of solar panels which are under the
seat of the passenger there is the rotation of the seat takes place. The two sources utilizing
wind and solar are major sources of charging the battery.

Chapter –4
Results& Discussions
Result & Discussions
_________________________________________________________________________________
Chapter-4 RESULT & DISCUSSIONS
_________________________________________________________________________________
4.1 Static Structural Analysis on Blade:

In this process optimum material suggested with the help of Ansys work bench and
each material strength has been discussed for optimum results in real time applications.
After completion of material selection here, we have to create meshing for each
object meshing means it is converting single part into no of parts. In addition, this mesh will
transfer applied loads for the overall object. After completion meshing only we can solve
our object. Without mesh, we cannot solve our problem. In addition, here we are using tetra
meshing and the model shown below.
Fig.4.1 Meshing
Meshing is a critical step in finite element analysis (FEA), which is a Numerical
method used to simulate and analyze complex structures and systems. In ANSYS, meshing
refers to the process of dividing a complex geometry into small, simple elements, which can
be used to perform FEA simulations.
Meshing in ANSYS lies in the fact that the accuracy and reliability of the simulation
results depend heavily on the quality of the mesh. A well-designed mesh can provide
accurate and reliable results, while a poorly designed mesh can lead to inaccurate and
unreliable results.
Dept of Mech.Engg ;VIIT; Visakhapatnam Page 35

4.1.1 Static Structural Analysis of PEEK Material:

In static structural analysis, the maximum pressure typically occur on the surface of the
blade facing the wind. This pressure can cause significant bending and deformation of the
blade, which can be analysed using finite element analysis (FEA) software.
Fig.4.2 Maximum Pressure of PEEK Material

Maximum Pressure that the blade can withstand is:6.e-003 MPa=13.3 MPa
During a static structural analysis, the FEA software calculates the stresses and
deformations within the blade caused by the applied loads, including the wind pressure.By
analyzing the results of the analysis, it is possible to determine the maximum pressure that
the blade experiences and the location where it occurs.
Knowing the maximum pressure and its location is important for designing and
optimizing wind turbine blades to withstand the forces they encounter during operation. It
can also help identify areas of the blade that may be prone to damage or failure, allowing for
modifications to be made to improve its performance and longevity.
Dept. of Mech.Engg,VIIT,Visakhapatnam Page 36

Fig.4.3 Maximum and Minimum Deformation of PEEK Material

According to the analysis, the maximum deformation is at the end of the blade and
minimum deformation is at the hub of the blade.
4.1.2 Stress Analysis of PEEK Material:
Fig.4.4 Maximum and Minimum Stress of PEEK Material

Maximum stress can be determined in a static structural analysis. In a wind turbine blade,
the maximum stress typically occurs in areas of high deformation or where the material
experiences the highest load.
During a static structural analysis, the FEA software calculates the stresses and
deformations within the blade caused by the applied loads, including the wind pressure. By
analyzing the results of the analysis, it is possible to determine the maximum stress that the
blade experiences and the location where it occurs.
Knowing the maximum stress and its location is important for designing and
optimizing wind turbine blades to withstand the forces they encounter during operation. It
can also help to identify areas of the blade that may be prone to fatigue or failure, allowing
for modifications to be made to improve its performance and durability.
4.1.3 Strain Analysis of PEEK Material:
Fig.4.5 Maximum and Minimum Strain of PEEK Material

The results of the strain analysis can help identify areas of the blade that experience high
levels of strain, which can then be modified to reduce strain levels and improve the

performance and longevity of the blade. This information can also be used to optimize the
design of the blade, such as by modifying its shape, thickness, or material properties.
Performing a strain analysis in ANSYS allows us to ensure that wind turbine blades can
withstand the stresses and strains they will experience during operation. This is essential for
ensuring the safety and reliability of the wind turbine, as well as for maximizing its energy
output and minimizing maintenance and repair costs.
4.1.4 Factor of Safety of PEEK Material:
The factor of safety is an important output parameter in structural analysis that helps to
evaluate the safety of a component under different loading conditions. In Ansys, the factor
of safety of a PLA material can be calculated using this formula:
Factor of Safety = Yield Strength of PLA / Maximum Von Mises Stress
=70/15
=4.6
The factor of safety value indicates the safety margin of the component, and a value greater
than 1 indicates that the component is safe for use under the applied loads. A factor of safety
value less than 1 indicates that the component is at risk of failure and may require redesign
or modification.
Fig.4.6 Factor of safety of PEEK Material

4.1.5 Static Structural Analysis of PLA Material:
In static structural analysis, The first step is to define the material properties of PLA
in Ansys. This includes inputting values such as density, modulus of elasticity, Poisson's
ratio, and yield strength. The next step is to create a three-dimensional model of the
component and mesh it to define the element size and type. The accuracy of the results
depends on the mesh quality and size.
After the meshing, boundary conditions such as constraints and loads must be applied. This
can include forces, fixed supports. Once the boundary conditions are applied, the analysis
can be set up by defining the solver options and specifying the desired output. After the
analysis is run, the results can be analyzed and interpreted. Typical outputs include stress,
strain, deformation, and safety factor.
The maximum pressure typically occur on the surface of the blade facing the wind. This
pressure can cause significant bending and deformation of the blade.
Fig.4.7 Maximum Pressure of PLA Material

Maximum Pressure that the blade can withstand is:5.e-003 MPa=10.59 MPa.
Fig.4.8 Maximum and Minimum Deformation of PLA Material

According to the analysis, the maximum deformation is at the end of the blade=23.5 mm and
minimum deformation is at the hub of the blade =0 mm.
4.1.6 Stress Analysis of PLA Material:
This is a commonly used measure of stress that takes into account all the stresses acting on a
material and provides a value that can be compared to the yield strength of the material.
Fig.4.9 Maximum and Minimum Stress of PLA Material

Maximum stress is at the joint of hub and blade and minimum stress is at the hub.
4.1.7 Strain Analysis of PLA Material: The results of the strain analysis can help identify
areas of the blade that experience high levels of strain, which can then be modified to reduce
strain levels and improve the performance and longevity of the blade.
Fig.4.10 Maximum and Minimum Strain of PLA Material

This information can also be used to optimize the design of the blade, such as by modifying
its shape, thickness, or material properties.
Performing a strain analysis in ANSYS allows us to ensure that wind turbine blades can
withstand the stresses and strains they will experience during operation.
4.1.8 Factor of Safety of PLA Material:
Factor of Safety = Yield Strength of PLA / Maximum Von Mises Stress
=50/15
=3.3
The factor of safety value indicates the safety margin of the component, and a value greater
than 1 indicates that the component is safe for use under the applied loads. A factor of safety
value less than 1 indicates that the component is at risk of failure and may require redesign
or modification.
Fig.4.11 Factor of safety of PLA Material

4.2 CFD Analysis:
CFD (Computational Fluid Dynamics) analysis on wind turbine blades involves
simulating the flow of air around the blades to evaluate their aerodynamic performance.
CFD analysis can be used to optimize the design of the wind turbine blades to increase their
efficiency and power output.
A 3D model of the wind turbine blade is created in a Fusion 360 software. This
model includes the entire blade structure, including its shape, size, and orientation.

Fig.4.2.1 Meshing in CFD analysis
The boundary conditions are defined, which includes the inflow velocity, wind
direction, and turbulence intensity.
A mesh is generated around the blade to divide the computational domain into small
cells for accurate analysis. A fine mesh is required for accurate results, but it also increases
the computational time.
The results of the simulation are analysed to determine the aerodynamic performance
of the wind turbine blade. The results include velocity distribution, pressure distribution, and
turbulence intensity distribution around the blade.
CFD analysis on wind turbine blades is an important tool in the design and
optimization of wind turbines. It helps to improve the efficiency and power output of the
wind turbine by optimizing the design of the blades.

4.2.1 At 40kmph:
Fig.4.2.2 Pressure at 40kmph

The results of a CFD analysis for a wind turbine blade operating at 40 km/h (11.11 m/s)
would depend on the design of the turbine blade.
The amount of pressure acting on the blade is 1.312e+00 Pa i.e., 3.56Pa.
At, higher wind speeds, the airflow around the blade can become turbulent, which can affect
the blade's performance. The pressure volume rendering technique can help us identify and
address design issues with the blade, such as optimizing its shape.
Fig.4.2.3 Velocity at 40kmph

Velocity volume rendering is a technique used in CFD analysis to visualize the airflow
around objects such as wind turbine blades. It can provide a detailed visualization of the

airflow around the blade at different wind speeds. By analyzing the velocity distribution and
identifying areas of high and low velocity.
The maximum Velocity is at the edges of the blade is 1.150e+01 i.e.,4.12m/s
4.2.2 At 60 Kmph, Pressure and Velocity:

The results of a CFD analysis for a wind turbine blade operating at 60 km/h (16.67 m/s).


4.2.3 At 80kmph, Pressure and velocity:



4.2.4 At 120kmph,Pressure and Velocity:


4.3 Practical Experimentation:
Placing a turbine Blade with a motor in front a bike, with the opposite air resistance
the turbine blade can rotate depending upon the speed of the vehicle.
The following values are experimentally generated
Table 4.3.1 Experimental Values:
4.4 Calculation Analysis:
 Dc Motor specification:
Voltage=24-36v, power=350w
Then-current according to formula P=VI
we get I=P/V =350/24= 14.58Amp
 Battery Specification: Voltage=24v,current rating=20Ah
Power=24x 20 =480watthour.
 To charge the battery while running off the vehicle so let us assume the battery needs
5hr to charge so we get 480/5= 96W.
 Hence current rating required is 96/24V= 4Amp.
 As per the calculation, The required voltage and current is24v and 4Amp.
***

Chapter – 5
Conclusions &
Future scope of work
Conclusions & Future Scope of Work
_________________________________________________________________________________
Chapter-5 CONCLUSIONS & FUTURE SCOPE OF WORK
6.1 Conclusions
The analysis and experimental investigation on a electrical vehicle led to the following
conclusions:
 The concept of integrating a wind turbine blade onto an electric vehicle to generate
electricity while the vehicle is in motion.
 The overall objective of the project is to develop a more sustainable and energy-
efficient transportation solution that can reduce the reliance on external charging
infrastructure and promote renewable energy use.
 The static structural and CFD analysis aims to evaluate the performance and
structural integrity of wind turbine blades.
 The project will also involve optimizing the design of the blade to improve its
structural efficiency and durability.
 Wind turbine blade that can withstand the stresses of operation and provide reliable
and efficient performance over an extended period of time.
6.2 Scope for Future work
 To maximize the energy generation from wind power, advanced wind turbines must
be developed that are compact, lightweight, and highly efficient.
 The future scope of electric vehicles (EVs) that can self-charge using renewable
energy is very promising. This technology has the potential to revolutionize the way
we think about transportation and energy use.
 One of the main benefits of self-charging EVs is that they can reduce our
dependence on non-renewable sources of energy, such as fossil fuels. This could
help to mitigate the negative effects of climate change and reduce air pollution in
urban areas. Additionally, self-charging EVs could provide a more sustainable and
cost-effective solution to our energy needs.
 There are already several companies working on developing self-charging EVs.
Some of these vehicles use solar panels on the roof to generate energy, while others
use kinetic energy from the wheels to generate electricity. In the future, we may see
even more innovative methods for generating renewable energy to power self-
Dept of Mech.Engg; VIIT; Visakhapatnam Page 49

Conclusions & Future Scope of Work
charging EVs.
 As technology continues to improve, we can expect to see self-charging EVs with
longer ranges and faster charging times. This could make EVs even more practical
and convenient for everyday use, as drivers will be able to travel longer distances
without needing to stop to recharge.
***
Dept. of Mech.Engg; VIIT; Visakhapatnam Page 50

Chapter – 6
References
References
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Chapter-6 REFERENCES
_______________________________________________________________________
[1] Rahul B. Gupta, “Design and Development of Electric Two Wheeler”,

Department of Automobile Engineering, Institute of Technology & Management,
Vadodara , Gujarat, India.
[2] K.W. Cheng ,“Recent Development on Electrical vehicles “ , Department of
Electrical Engineering, The hong kong Polytechnic University, Hong Kong . June
2009
[3] Suchismita Nayak, ”Status of electric vehicles charging methods”, Department of
Electrical Engineering, National Institute of Technology Durgapur, INDIA [5]
ASTM G99-95 Standard Test Method for Wear Testing with a Pin-On-Disk
Apparatus.
[4] Sanjay Gupta and Rehana Praveen,”A Review on Hybrid Electric Vehicles and
Power Sources”.
[5] “FABRICATION AND EVALUATING THE PERFORMANCE OF SMALL
SIZE WIND TURBINE BLADES with R21 and R22 Profiles” by T. Vishnuvardhan
and B. Durga Prasad, DOI-AA072011006 July 2011.
[6]“DELAMINATION BUCKLING ANALYSIS FOR DESIGN OF
HORIZONTAL AXIS WIND TURBINE (HAWT) COMPOSITE BLADES” by H.
Ghasemnejad, A. Maheri.
[7] “FINITE ELEMENT ANALYSIS AND EXPERIMENTAL INVESTIGATIONS
ON SMALL SIZE WIND TURBINE BLADES” by T.Vishnuvardhan, Dr.B.Durga
Prasad, Volume3, Issue3, September- December (2012), pp.493-503© IAEME:
Journal Impact Factor (2012).
[8] E.N. Jacobs, K.E. Ward, & R.M. Pinkerton. NACA Report No. 460, "The
characteristics of 78 related airfoil sections from tests in the variable-density wind
tunnel" (http:/ / hdl. handle. net/ 2060/ 19930091108). NACA, 1933.
[9] Chauhan, S.R., Kumar, A., Singh, I.: Sliding friction and wear behavior of vinyl
ester and its composites under dry and water lubricated sliding conditions, Materials
and Design, Vol. 31, p.p. 2745-2751, 2010.
[10] Theodora – elli stamsti, and Pavol baver, ”A Review on Electric Vehicles:
Technologies and Challenges “, Computer Science and System Engineering
Department (DIIS), University of Zaragoza, Atarazana, Teruel, Spain.

References
[11] Hemavathi and A shisha,” A study on trends and developments in electric

vehicle charging technologies”
[12] Manmeet Singh and Ravindra jilt, Development of experimental facility for
testing battery thermal management system of electrical vehicle.
***

Publication
Publication
Project Biography
PROJECT BIOGRAPHY
Batch No: 5
Project Mentor
Name: Dr. Dr.Girish E. Bhiogade

Designation: Assoc. Professor,
Mech. Engg Dept. ,VIIT Vizag
Email ID: [email protected]
Mobile No:9890918019
Project batch students
Name: Mahadas Vamsi Name: Matha Lova Kumar Name: Rambhatla Name: Kenguva
Regd No: 19L31A0309 Regd No: 19L31A0329 Tanmayee Dhrakshayani
E-Id: [email protected] E-Id: [email protected] RegdNo:19L31A0340 RegdNo:19L31A03A6
Mobile No: 9391452270 Mobile No:9573817315 EId::tanmayisharmarambhatla@gm EId:lkenguvadhrakshayani2028@g
ail.com mail.com
Mobile No: 8019220626 Mobile No:9010070270
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EXPERIMENTAL INVESTIGATION ON A NEW GENERATION

ELECTRIC VEHICLE USING RENEWABLE ENERGY

Project Work Report

MAHADAS VAMSI 19L31A0309

Under the Guidance of

Department of Mechanical Engineering

MAHADAS VAMSI 19L31A0309

Under my Guidance in partial fulfillment of the requirements for

Project Guide Head of the Department

MAHADAS VAMSI 19L31A0309

Dept of Mech Engg, VIIT, Visakhapatnam (i)

4.1 Static Structural Analysis on Blade 35

CHAPTER No. LIST OF FIGURES Page No

1.2 History about Electric Vehicle

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Fig.1.3 Classification of Electrical Vehicles

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1.3.1 Battery Electric Vehicles (BEVs):

Fig.2.3.1 Battery electric vehicle

Fig.1.3.2 Plug-in Hybrid Electric Vehicle.

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Fig.1.3.3 Hybrid Electric Vehicle

Fig.1.3.4 Fuel Cell Electric Vehicle

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1.3.5 Extended Range Electrical Vehicles (ER-EVs)

1.4 Neighborhood Electric Vehicles (NEVs)

1.5 Main Components of Electric Vehicle:

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1.5.2 Electric Motor:

Electric motors have become a vital component of modern technology, powering

Dept. of Mech Engg , VIIT ,Visakhapatnam Page 7

1.5.2.1 Types of Electric Motors:

1.5.2.2 Permanent Magnet Synchronous Motor:

Dept. of Mech Engg , VIIT ,Visakhapatnam Page 8

wide range of applications, including electric vehicles (EVs).PMSMs have several

Fig.1.5.2 Permanent Magnet Synchronous Motor

1.5.2.3 Induction Motor:

An induction motor is a type of electric motor that uses electromagnetic induction to

Dept. of Mech Engg , VIIT ,Visakhapatnam Page 9

Fig.1.5.3 Induction Motor

1.5.2.4 Switched Reluctance Motor:

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Fig.1.5.4 Switched Reluctance Motor

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1.5.2.5 Brushless DC Motor:

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Fig.1.5.5 Brushless DC Motor

1.5.3 Power Electronics:

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1.5.4 ON Board Charger :

An on-board charger is a device installed in an electric vehicle (EV) that is responsible

DC fast charging provides an even faster charging rate by using high-power DC

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Fig.1.5.6 On Board Charger

A DC-DC converter is an electronic device used in electric vehicles (EVs) to convert

Dept. of Mech Engg , VIIT ,Visakhapatnam Page 15

1.5.6 Thermal Management System:

Thermal management systems (TMS) are critical components of electric two-wheelers