Abstract
In recent years, the new energy vehicle industry has been vigorously developed, and the demand for new energy vehicle practitioners and their knowledge of electric vehicles has been continuously increasing. In the undergraduate education of vehicle engineering, there is an urgent need for an electric drive demonstration teaching platform. This design aims to solve the teaching demonstration function of multiple configurations of electric vehicle drive systems on the same platform. The electric vehicle drive demonstration teaching platform is designed as an expandable way, which can meet the requirements of various combinations of different motor forms, battery types and capacities, control methods, etc. for platform loading and demonstration, achieving diversification of the teaching platform. It can also conduct experiments on various types of new energy vehicle configurations through connecting racks The expansion of the demonstration teaching platform meets the needs of teaching demonstrations and experiments related to electric vehicle drive systems.
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1 Introduction
The development of new energy vehicles has now become a national strategy, which is of great significance in alleviating environmental and energy pressures, promoting the transformation and upgrading of the automotive industry, It is particularly important to carry out research and development of new energy vehicles [1,2,3,4]. In recent years, China's new energy vehicle industry has achieved significant development, with the production and sales of new energy vehicles continuously increasing and the market share increasing year by year. In 2022, the production and sales of new energy vehicles for the entire year were 7.058 million and 6.887 million, respectively, with year-on-year growth of 96.9% and 93.4% [5, 6], maintaining the world's first place for 8 consecutive years. The sales of new energy vehicles accounted for 25.6% of the total sales of new vehicles.
With the transformation and development of automotive power from traditional fuel to new energy, the original curriculum system of Vehicle Engineering can no longer fully meet the training needs of talents. Vehicle Engineering majors in various universities are actively exploring and reforming, introducing courses related to the research and development, manufacturing, and other aspects of new energy vehicles, so that students can initially master the theoretical knowledge and practical abilities of new energy vehicles in their studies. The number of new energy vehicle products continues to grow, the learning experience gained from using Electric Vehicle Drive Demonstration Teaching Platform will prove to be very valuable for further development in this field, and it is of great significance for the progress of electric vehicle technology education [7, 8]. For application-oriented undergraduate education, while learning relevant theoretical knowledge, it is particularly urgent to focus on practical abilities, combine theory with practice, and design a teaching demonstration platform that corresponds to the theory of new energy vehicles to meet students' learning needs [9, 10].
The motor drive system is an important part of the three electric system of new energy vehicles. The learning, understanding and application of the motor drive system is the key point in the teaching process of new energy vehicles for application-oriented undergraduates. The development and design of the demonstration teaching platform of the motor drive system can enable students to deepen their learning and understanding in building the motor drive system, completing the function demonstration, understanding the working mode of the motor, and better integrate with theoretical knowledge.
Electrification in the automotive industry appears in the form of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs). Different configurations of HEVs, namely series, parallel, and series–parallel [11, 12], for the above reason, as well as the various configurations of electric vehicles such as two wheel drive and four wheel drive, as well as various types of driving motors such as DC and AC motors, as well as various forms of batteries such as lead-acid batteries and lithium batteries, the battery capacity, volume, and interface size of different systems also vary, and the controller form, quantity, and connection method of different systems also vary. If a driving demonstration teaching platform is designed for each different situation, A large amount of resources need to be invested, resulting in the waste of teaching and experimental sites and an increase in equipment management and other aspects of work. Designing the electric vehicle drive demonstration teaching platform as an expandable approach can meet the compatibility of the teaching platform with different motor forms, battery types and capacities, and control methods, achieve diversification of the teaching platform, better meet the needs of electric vehicle drive system related demonstrations and experiments, reduce resource and venue waste, and reduce management and maintenance costs.
2 Composition and Principle of Electric Vehicle Drive System
The motor drive system of electric vehicles is one of the core components of electric vehicles. Its core components are generally composed of motors, controllers, power converters, mechanical transmission devices, etc. in order to ensure that the motor drive system can work according to the driver's intention, it is necessary to connect the corresponding operating mechanism and sensors, and at the same time, there is a battery pack for its energy supply [13,14,15]. Its basic composition structure is shown in Fig. 1.
Composition of electric vehicle drive system
As shown in Fig. 1, the battery pack provides energy for the motor drive system. The controller receives signals such as throttle, brake and speed, judges the driver's intention, and sends out control signals. The control power converter provides the corresponding voltage or frequency to drive the motor, and finally drives the mechanical transmission device to meet the driving requirements of the vehicle.
The display and understanding of the principle of electric vehicle drive system, the connection between various physical components and the realization of control strategies are the key contents of undergraduate education. Especially for application-oriented undergraduate education, students should be able to correspond the corresponding components with the physical object, connect them according to the principle, complete the drive control, and deeply understand the realization and control of motor drive system. The expandable demonstration teaching platform for electric vehicle drive can carry and demonstrate different batteries, controllers, motors and drive devices to meet the teaching needs.
3 Design Requirements of Electric Vehicle Drive Demonstration Teaching Platform
For teaching experiments of courses related to new energy vehicle technology, the driving demonstration teaching platform shall be able to display various functional modules, and students shall be able to conduct physical connection of mechanical and electrical aspects according to the operating principle, so as to realize the driving function, monitor relevant parameters and analyze the driving state.
The new-energy vehicle includes a variety of design forms such as pure electric vehicle, hybrid vehicle and extended-process vehicle. The structure of pure electric vehicle is typical, and the composition is relatively simple, which is more conducive to students' learning and understanding. Later, the driving device of driving pure electric vehicle serves as a demonstration teaching platform, and the structure is simpler, the composition is clearer, and it is more consistent with the requirements of application-oriented undergraduate experimental teaching. From the analysis of the composition of pure electric vehicles, pure electric vehicles have different compositions in terms of driving mode, control method, battery capacity, etc. Therefore, the design of driving demonstration teaching platform shall comprehensively consider the realization of various functions, and shall consider its extensibility to meet the needs of demonstration and teaching, and make corresponding preparation for the future platform expansion.
4 Scheme Design of Electric Vehicle Drive Demonstration Teaching Platform
Based on the demonstration and teaching requirements of the electric vehicle drive demonstration teaching platform, the specific design of the program shall first meet the hardware installation and functional connection, and then shall be able to control the drive system through the operating device after the completion of the connection, and display the operation status on the instrument. The schematic composition of the system is shown in Fig. 2.
Principle composition of electric vehicle drive demonstration teaching platform system
For the convenience of control, the demonstration teaching platform uses DC motor as the driving device. The motor is connected with the driving wheel of the axle through the reducer and differential, so as to complete the driving of the tire to simulate the running of the electric vehicle. The control of the motor is completed through the controller. The control signal can be input by the hand throttle or the foot throttle. The deceleration is completed by the mechanical brake of the hand brake or the foot brake. The energy is provided by a group of batteries, the voltage and capacity required by the matched motor, motor speed, speed, current, voltage and other information are displayed on the combination instrument to analyze the corresponding working conditions. The 3D design drawing is shown in Fig. 3.
Three dimensional design of electric vehicle rear drive debugging teaching platform
5 The Design Scheme of Expanded Capacity of Electric Vehicle Drive Demonstration Teaching Platform
In the design of an electric vehicle drive demonstration teaching platform, full consideration should be given to its expansion ability. The implementation of expansion ability can generally be achieved by increasing the installation points and holes on the support platform, lengthening the design platform, and improving the loading capacity of the platform. A dedicated mechanism should be designed to enable the support platform to have lifting function, meeting the installation needs of more components of different specifications and dimensions. At the same time, there is sufficient expansion space and installation location reserved at the control display desk to meet the installation and connection requirements of control and display equipment.
In order to meet the expandable design requirements of the teaching platform for electric vehicle rear drive debugging, different specifications of motor drive axles and batteries are installed in teaching to form different driving modes. The speed and torque of the motor on the motor drive axle are controlled by the drive motor controller. In the overall design, the mounting base and support platform are designed respectively. The support platform is composed of fixed connecting frame and mounting frame, A number of mounting holes are equally spaced on the surface of the mounting frame and the connecting frame to facilitate the installation of motor controllers, display instruments, control devices and other components of different sizes on the mounting frame. The motor drive axle is fixed by bolts at the lower end of the mounting frame, and batteries or other energy storage and energy supply devices are installed on the fixed connecting frame. The components are connected by wire harness to achieve relevant experimental debugging and demonstration functions, Its basic structure is shown in Fig. 4. At the same time, in order to realize the adjustable height and position of the bench, an adjustable supporting platform height adjusting mechanism is designed on the inner wall of the mounting base to meet the installation requirements of different motors and drive axles.
Basic structure of electric vehicle rear drive debugging teaching platform
In order to realize the adjustability of the electric vehicle rear drive debugging teaching platform, a special structural design was carried out. The handle can be turned to drive the screw column to rotate, which can drive the screw transmission between the nut seat and the screw column, so as to drive the slider to move, so that the first support rod and the second support rod can push the support platform up and down, so as to adjust the height of the mounting bracket, which is convenient for the installation of the motor drive axle and other components, It can also meet the installation of motor drive axles and other components of different specifications and models. The specific mechanism is shown in Fig. 5.
Basic structure of support frame
The design configurations of new energy vehicles are diverse. Pure electric vehicles, hybrid vehicles and some new types of new energy vehicles are constantly developing new technologies. This platform can also further expand the structure at the connecting frame and connect more external devices, laying the foundation for the subsequent expansion of various types of new energy vehicle driving teaching demonstration platform.
6 Conclusion
With the rapid development of China's new energy vehicle industry, the demand for employees of new energy vehicles continues to rise. Due to the diverse configurations of new energy vehicles, it is particularly necessary to design and develop relevant teaching and experimental equipment with good expansion performance, which has become the hardware basis for cultivating students' practical ability. On the basis of meeting the basic principles of electric vehicles, debugging and demonstration, the extensible electric vehicle drive debugging teaching platform designed and developed in this design has deeply considered the extended transformation performance to meet the requirements of subsequent experimental demonstration of different configurations of electric vehicles, and has played a corresponding role in promoting the teaching of electric vehicles.
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Zhao, Z., Chen, Z., Huang, S., Fan, J., Gao, L. (2024). Design of Expandable Electric Vehicle Drive Demonstration Teaching Platform. In: Halgamuge, S.K., Zhang, H., Zhao, D., Bian, Y. (eds) The 8th International Conference on Advances in Construction Machinery and Vehicle Engineering. ICACMVE 2023. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-97-1876-4_19
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