Design and Development of an Intelligent Multi-Utility Electric Vehicle Powertrain System with Smart Energy Management

Abstract

Due to the growing demand for sustainable modes of transport, alternative vehicles to the traditional internal combustion engine (ICE) vehicles, such as electric vehicles (EVs) are being developed quickly. But most of the current EVs are designed specifically for transportation use, and they cannot be adapted to a wide range of transportation and industrial applications. This paper discusses the research and development of a Multi-Utility Electric Vehicle (MUEV) Powertrain System that supports a variety of applications using a lightweight and modular design. An improved chassis, motor controller, lithium-ion battery pack, and Permanent Magnet Synchronous Motor (PMSM) are all part of the suggested system, which aims to enhance performance, dependability, and efficiency. The chassis was designed in Autodesk Fusion 360 and tested in ANSYS Workbench for deformation, stress distribution, buckling resistance and crashworthiness for the front impact scenario. A combination of weight optimization techniques allowed the chassis to retain almost 51% of its weight without compromising on its structure. The Worldwide Harmonized Light Vehicles Test Cycle (WLTC) and SIMCENTER Amesim/MATLAB simulation software were used to analyse the vehicle dynamics, battery State of Charge (SOC), motor efficiency, torque characteristics and driving range. The recommended design was tested for the motor and the controller. The simulation had resulted in efficient running of the motor, the battery had not shown any changes in performance and the torque had been transmitted through the integrated gearbox, with a maximum speed of 32 km/h. It can be easily adapted to other uses, such as passenger carrying, goods transport, industry, and other utilities. In summary, the MUEV power train is an efficient solution, both in terms of weight and cost, that can help to realize sustainable mobility, increase the adaptability of vehicles and facilitate future electric mobility systems.