A Paper on Advances in Automobile Engineering Submitted by 1. Shivshankar R. Gun ote gun otes#gmail.com "ob.%o&' ()(*1(*)!( !. Sanved ".

"athpati sanvedm$$#gmail.com "ob. %o& ' ()(*+,$1,+

-.ollege o/ Engineering0 Pandharpur1

At 2E.3445GE%2 6 !))( P5"PR5 .35%.3A7A8 .944EGE 9: E%GG. P;%E Abstract
The design and manufacture of lightweight electric vehicles is becoming increasingly important with the rising cost of fuels, and the effects emissions from Fuel powered vehicles are having on our environment. The University of Waikato and Hybrid Autos Ultracommuter electric vehicle was designed, manufactured, and tested. The vehicle has been driven over !""km with only a small reliability issue, indicating that the Ultracommuter was well designed and could potentially be manufactured as a solution to ongoing transportation issues. The Ultracommuter pro#ect was deemed a success by the vehicles completion and participation in the World $olar %hallenge &""'. The results for pro#ect of this nature do not lend themselves to be easily #udged( rather the vehicles success largely depends on its comparison to a conventional internal combustion engine vehicle.

5%2R98;.259% The Ultracommuter is an advanced electric vehicle designed for short range commuting. The University of Waikato and HybridAuto have designed and built a prototype electric vehicle. The car is based on a simple design concept incorporating five factors( producing a complete design solution, a lightweight vehicle design, using advanced manufacturing techni)ues, being energy efficient, and using modern materials.
%omplete +esign $olution

.ight weight ,nergy ,fficient Ultracommuter /ehicle

Advance manufacturing
Techni)ues

-odern -aterial

:ig.1 ;42RA.9"";2ER 8esign .oncept ;42RA.9"";2ER .9"P9%E%2S A%8 S<S2E"S The structure and design of an ;ltracommuter engines with four main design areas.As shown in Figure *. the chassis, the mechanical components, the electronics, and the body shell make up a battery electric vehicles design

0attery ,lectric /ehicle

%hassis

-echanical %omponents

,lectronics

0ody $hell

:ig.! .omponents o/ ;42RA.9"";2ER

"A5% 8ES5G% AREAS 9: ;42RA.9"";2ER Electronics

:ig.= 8esign Areas o/ Electronics

,lectronics

1igh 2ower ,lectronics

.ow 2ower ,lectronics

0atteries 3 %harging

-otors 3 +rives

Telementry 3 1U+

.ighting 3 %omfort

0attery -onitoring

,lectric -otors -otor %ontrollers 3 4nductors

0attery -onitoring 3 management $peed and -otor +ata

,5terior .ighting

%harger

4nterior .ighting Air conditioning

,ntertainment

The electronic components in an electric vehicle are the newest technology in the vehicle. The high power electronics of batteries, motor controllers, and motor are all integrated with a low power system including telemetry, lighting, and entertainment.

"echanical .omponents The mechanical components in a battery electric vehicle mainly consist of the rolling stock. The suspension, steering and braking are the main subgroups of the mechanicalcomponents.

-echanical %omponents

$teering

$uspension

0raking

6ack

%olumn 3 Wheel

Wishbones Upright etc

$hocks 3 $uspension

$uspension -ounts

0rake,+isc 3 %alipers

:ig. , Areas o/ "echanical .omponents .9"P4E2E ;42RA.9"";2ER .A8 "98E4 The use of %A,, or virtual engineering, was evident throughout the design of Ultracommuter. A complete model was designed in $olidWorks, and all components were integrated into the %A+ model before production began. Fig.shows the complete $olidWorks model of the Ultracommuter.

:ig.> .A8 "odel o/ ;ltracommuter

.9%2R944ER AREA %E279R? The %A7 8%ontroller Area 7etwork9 is a serial communications protocol that geared towards providing an efficient, safe, cost effective network for control applications. 4t was designed by 6obert 0osch :mb1 for use in vehicles and has been adopted widely throughout industry for automotive and industrial automation applications where distributed control of a system is re)uired.The .A%!;S@ bridge allows any U$0 e)uipped computer to communicate on the %A7 network in the Ultracommuter. This allows a person to view the network traffic and send data onto the network. To bridge %A7 to U$0, a processor is used to translate the data from one network, interpret it and repackage it for the other network. 4n addition to the basic bridge functionality, it can also filter out %A7 packets before they get to the 2% to reduce 2% processing and U$0 bandwidth re)uirements. ;42RA.9"";2ER 2E.3%5.A4 SPE.5:5.A259%S @AS5.S %onfiguration 0ody %hassis $i>e .=W=1 Wheelbase %urb mass PoAer Sources 0attery $olar panel 6ange e5tender Fuel storage Per/ormance Top speed; -a5imum electric driving range; -a5imum range with %7: range e5tender; $olar<only driving range; ,lectric energy consumption; ; A"km=h 8limited9 ; A""km ; Up to A"km per day ; A"Wh=km ; .ithium 4on B "" cells, *?"/ nominal, !.?kWh, ?"kW, 'Akg ; roof<mounted, *'AW, &.Am&, AC efficiency ; "kW natural gas<fuelled engine=generator ; *?. compressed natural gas D *?""psi ; & door, & seat, sports coupe ; fiber composite panel ; hydro<formed=bonded aluminium ; *!""= ?""= *""mm ; @""mm ; AA"kg

%harging system ; onboard solar charger with au5iliary wall cord=plug

; &""km

;42RA.9"";2ER 8ES5G% SPE.5:5.A259% The Ultracommuter pro#ect had two main ob#ectives To compete at the &""' World $olar challenge To be a working prototype electric vehicle. 0ecause of these two factors, the Ultracommuter had a uni)ue design specification. 4t was not designed purely for a commercial or prototype view point and some %ompromises were made to allow the vehicle to compete in theWorld $olar challenge Per/ormance The vehicle must be able to do " km=h.The Ultracommuter is to have A""km range per day.The car must reach performance and safety re)uirements of the low/olume vehicle transport authority 8.//TA9.The car must handle well and corner easily. 4t must perform all norm driving manoeuvres 8U<turn, reversing etc9.The car must use appro5imately E the energy re)uired by a combustion engine powered car. Environment The Ultracommuter will be used outdoors in a wide range of weather conditions so the construction of the vehicle must withstand outside temperatures ranging < " % to A"%, and must also be waterproof and wind resistant. "aintenance -aintenance on the Ultracommuter should consist of no more than a gasoline powered car. -aintaining the batteries and electrical system will be the ma#or maintenance completed on the car. -aintenance shall be easy to complete and must be designed so that a mechanic and auto electrician are able to complete it. 2arget Product .ost -anufacturing cost must be no greater than F@A,""" 7G+ "aterials The Ultracommuter will be built from as many natural products as possible, with an emphasis on lightweight advanced materials that meet the 2erformance re)uirements. Ergonomics The car must be designed so that everyone from the AC Female to the HAC -ale can operate the vehicle.

2esting %omponents and the design of the car will be tested using several methods. The cars design will undergo F,A and %F+ testing. Where possible, components, or materials of the components will undergo standard tests 8tensile etc9. 6oad testing will be completed on the car prior to the completion. Sa/ety 0oth the cars operators and observers must be under no danger while the car is stationary or driving. From the design concepts and this design specification, the Ultracommuter was designed and built with the ultimate goal of driving in the World $olar %hallenge in H months.

;42RA.9"";2ER AER98<%A"5.S Aerodynamics describes the performance of a shapes movement through a fluid 4n the case of a vehicle, aerodynamics represents anything that affects the cars movement through the air, for e5ample, the vehicles body, and appendages such as wings, spoilers, and mirrors. 4nternal flows are also a focus of aerodynamics, including air conditioning, and wound down windows. Aerodynamics is responsible for the greatest concessions to design and styling. The basis for aerodynamics on vehicles is to try and minimise the amount of boundary layer separation, which is when the air flow breaks away from the flow profile and creates turbulence.

Fig. shows the sur/ace area of Ultracommuter. The Ultracommuter has a small surface area of .@&m& with no wing mirrors

.9%.4;S59% +eveloping a lightweight electric vehicle re)uires the use of the modern materials and engineering techni)ues. -ost importantly, the design of a lightweight vehicle must integrate all of the components together in a way that allows for the minimi>ation of weight.

:;2;RE S.9PE The future of lightweight electric vehicles looks bright, with government incentives for both owners and manufacturers to push our personal transportation needs to a more sustainable system. The latest developments in battery technology, allow electric vehicles to continue to improve their performance including sports car type acceleration and long ranges of *""km.

Actual ULTRACOMMUTER

RE:ERE%.ES
. Travis de Fluiter, Design of Lightweight Electric Vehicles, The University of Waikato, 7ew Gealand, -arch<&""!. &. 1appian<$mith, I. An Introduction to Modern Vehicle Design; ,lsevier, &"" . *. 1ussain, 4. Electric and Hybrid Vehicles design fundamentals, Florida, &""*. @. Iohnson T., Hobby Car Technical Manual, 1ot 6od Association, 7ew Gealand,&""'. A. www.hindustantimes.com ?. http;==en.wikipedia.org '. http;==www.carbodydesign.com