Riset dan PengembanganKendaraan Listrik di ITS

Dr. Bambang SudarmantaSains Techno Park Otomotif

Direktorat Inovasi dan Kawasan Sains TeknologiInstitut Teknologi Sepuluh Nopember

Dipresentasikan Pada:Webinar Penguatan Industri Sepeda Motor Listrik Nasional Untuk Mendukung Substitusi Impor

Balai Riset dan Standarisasi Industri SurabayaSurabaya, 4 Nopember 2020

ROADMAP INOVASI ITS DI BIDANG OTOMOTIF

MOLINA

GESITS 1.0FIN KOMODO VEHICLEELECTRIC BUSCONVERSION ICE TO BEV

AUTONOMOUS CAR

HEALTH BIKE

ELECTRIC VEHICLE

Center of Excellence

Research - Design - Engineering - DevelopmentITS TECHNO PARK : Automotive - Creative - ICT Robotics

GESITS 2.0

Acceleration of Battery Electric Vehicle Program for Road TransportationPERPRES 55 TAHUN 2019

PT. WIKA Industri Manufaktur

BASIC RESEARCH

APPLIED RESEARCH

PROTOTYPING PRODUCT

MERKETING

COMMERCIAL DIFFUSION

Braja Wiksa Udeo

PERKEMBANGAN TEKNOLOGI OTOMOTIF

1900 : Carburetor

1990 : Fuel injection2000 : DOHC + Variable

valve timing

2005 : Hybrid EngineCombined of ICE & EV

(Low Emission)

2010 : Fuel CellHydrogen-fueled electric

car(Zero Emission)

TINJAUAN DERAJAT ELEKTRIFIKASI KENDARAAN LISTRIK

KATEGORI KENDARAAN LISTRIK

STRUKTUR TOPOLOGI PLATFORM KENDARAAN LISTRIK BATERAI

DC to DCConverter

• E-Bicycle

• E-Motorcycle

• E-Three Motorcycle

• E-Car

• E-Bus & E-Truck

Based on new dedicated

platform for EVs

• E-Motorcycle

• E-Three Motorcycle

• E-Car

• E-Bus & E-Truck

Based on Conversion from ICEVs

•Electric motor

•Controller of Electric motor

•Battery dan BMS

•Chassis and body

•Integrated Vehicle Computer

Based on integration of

main parts industry for EVs

BEVs Platform based on:• Innovation • Synergy between

•Academic•Business •Government

•Natural resources•Main parts Industry for EVs•Renewable energy• Environmental friendly•High Domestic Content

Level•User facility services

KONSEP & STRATEGI PENGEMBANGAN KENDARAAN LISTRIK

1

2

3

PERATURAN PENGEMBANGAN KENDARAAN LISTRIK

Peraturan Menteri Perindustrian No 27 2020 tentang spesifikasi, peta jalan pengembangan, dan ketentuan penghitungan nilaitingkat komponen dalam negeri kendaraan bermotor listrik berbasis baterai

PERATURAN PENGEMBANGAN KENDARAAN LISTRIK

Peraturan Menteri Perindustrian No 27 2020 tentang spesifikasi, peta jalan pengembangan, dan ketentuan penghitungan nilaitingkat komponen dalam negeri kendaraan bermotor listrik berbasis baterai

1. DEVELOPMENT BASED ON NEW DEDICATED PLATFORM FOR EVs

E-Scooter GESITSSPECIFICATION

Type : Scooter

Capacity : 2 passangers

Years : 2017

Battery : Li Ion 3,8 kWh

Electric Drive : BLDC Axial 5 kW

C/W Controlloer

Chassis : Tubular Chassis

Suspension : F Telescopic

R Monoshock

Brake : F/R Disc Brake

Wheel : F80/90 R14 ;

R90/90 R14

Torsi : 17 Nm @1400rpm

Charging : 2 Hours

Dimensi : 1.910 x 695 x 1.100

mm

Wheel Base : 1.350 mm

Ground Clearence : 200 mm

Weight : 110 Kg

E-Scrambler

E-Caferacer IoT

DrivetrainThrottle Control Ride-by-wire Electric Throttle

Motor Axial Permanent Magnet Synchronous Motor

5kw rated, 10kw peak

Cooling System Air Cooling System

Transmission Chain 1:3 ratio

Max. Power Output 10kw @2800 rpm

Max. Torque 281 Nm @ 0-2500 rpm

Pow er Control SystemVoltage Operation 72V -90V

Max. Current 500A

BatteryBattery Type LIFEPO4 EVE 50A

Voltage 72V

Capacity 3,6kwh

PerformanceAcceleration (0-60 km/h) 4 sec

Max. Speed 120 km/h

Max. Riding Range Approx. 100km

DimensionLength x Widt x Height 2.010 mm x 710 mm x1.110 mm

Wheel Base 1.480 mm

Gross Weight 160 Kg

FrameChassis Steel Chassis

Front Suspension Telesopic

Rear Suspension Double shock

Brake System (Front/Rear) Double Disk Brake

Wheel (Front/Rear) 120/60-R187/160/60-R17

SafetyHeadlight LED

Stoplamp LED

Sign LED

A. Wheel Base: 2100 mmB. Overall Length: 3320 mmC. Overall Height: 1780 mmD. Tire Diameter: 545 mm (R15 185/55)E. E. Ground Clearance: 140 mmF. F. Height Position LIDAR: 770 mm

E-CITY CAR

PERFORMANCE

Objective to get:

TOP SPEED & GRADEABILITY

According to your wants & needs

By determining:

Electric motor technical specifications:

Power, Torque, Consumption & RPM

Prevent vehicles from :

SLIP, SKID, AND ROLL

VEHICLE STABILITY

By determining:

Load distribution

Noted:

Another focus in the design is the selection of the type, size and capacity of the battery and other vehicle components

CONVERSION STRATEGY DETAILS

SAFETY FACTORS

Prevent vehicles from:

Electrical shock & Overheat

By determining

Warning & Security System

2. DEVELOPMENT BASED ON CONVERSION FROM ICEVs

θGradeability: - Calculation of traction force & drag- Resistance force : 𝐹𝑟 = 𝐹𝑎𝑒𝑟𝑜 + 𝐹𝑟𝑜𝑙𝑙 + 𝐹𝑐𝑙𝑖𝑚𝑏

PERFORMANCE – Gradeability

1. Load distribution design2. Center of Gravity calculation3. Stability Calculation

Stability analysis in turning vehicle dynamics:• Avoid Slip• Avoid Skid• Avoid Roll

VEHICLE STABILITY

1. Protection from electrical contact: direct & indirect2. Battery Evaluation: Battery specifications, Markers, & cable installation3. Operating safety:

• Warning system when going to drive,• When leaving the vehicle • When charging the battery

4. Hydrogen emissions: threshold mainly for lid acid batteries5. Car sound: give awareness to surroundings by adding a sound-producing

device to the EV car

SAFETY FACTORS FOR BEVs

BASED ON ICEVs

ICE Vehicles

Conversion Strategy

Conversion ICEVs to BEVs Strategy

• Performance • Top speed• Gradeability• Power & Torque• Speed• Fuel consumption

• Safety Factor• Electrical shock• Over heat

• Stability • Avoid Skid, Slip and Roll• Load distribution• CoG

• IoT-based on IVC facility • Performance• Maintanance• Service

Electrical Vehicles

Electrical Bus

Conversion Strategy

BASED ON DIESEL ENGINE BUS

Conversion ICE Bus to BEVs Bus Strategy

• Performance • Top speed• Gradeability• Power & Torque• Speed• Fuel consumption

• Safety Factor• Electrical shock• Over heat

• Stability • Avoid Skid, Slip and Roll• Load distribution• CoG

• IoT-based on IVC facility • Performance• Maintanance• Service

Diesel Engine Bus

3-Phase BLDC Motor Controller Suitable Trapezoidal & Vector

Control Power up to 90 kW (tested on

60KW) Hall Effect Sensor Efficiency > 90 % Voltage Max 450 VDC Isolated (Galvanic Isolation) Using 3 IGBT CAN Bus 2.0B 250 Kbps Programmable Controller Frequency 20 kHz Water Coolant

Electric Vehicle Parts

Analysis of Bus Chassis Stability

ICE

BEV LAYOUT 1

BEV LAYOUT 2

Wheelbase : 3850 mmCoG Comparison :Distance from front wheel:

• ICE : 2106.68 mm• BEV 1 : 2210.87 mm• BEV 2 : 2455.44 mm

Distance from rear wheel:• ICE : 1743.32 mm• BEV 1 : 1639.13 mm• BEV 2 : 1394.55mm

Develop Low Entry bus Chassis System

3. DEVELOPMENT BASED ON INTEGRATION OF MAIN PARTS INDUSTRY FOR EVS

R&D BATTERY PACK

Design

Simulation

Cell Testing

PrototypingRefers to UNR.100

Cell Assembly & welding

Terminals

Product

• Development of electric motors type:• BLDC • SRM

• Fully programmable• Synchronize with regenerative brake system• CAN-BUS communication• Independently fabrication :

• By ITS-start up • Starting with computer design • Computer simulation for performance

• Cooling system:• Water cooling• Air cooling

• Compact dimensions• High domestic content level

DEVELOPMENT OF ELECTRIC MOTORS

• Applications on:• E-Bicycle• E-Motorcylce• E-Three motorcycle• E-Car • E-Bus & E-Truck

BLDC Motor Controller :• Max Power & voltage: 90 kW, 450 VDC and working

frequency 20kHz• Independently fabrication :

• By ITS-start up • Starting with computer design • Computer simulation for performance

• Be equipped:• Hall Effect Sensor as feedback for rotor speed and

position• 3 Insulated Gate Bipolar Transistor (IGBT)• Isolated Gate Driver as well as Isolated Voltage

Sensing• CAN Bus 2.0B communication system with 250 Kbps

speed• Programmable Controller to synchronize parameters with

motor• Cooling using a water coolant• High domestic content level

DEVELOPMENT OF ELECTRIC MOTOR CONTROLLER

Wiring Diagram Controller

Reconfigurable Battery Pack, adaptive:• Variation of power rating• Voltage rating• Limitations of space, weight and duration of

charging• Can be implemented on electric buses• High domestic content level

Battery Management System • Able to balance the voltage between cells• Safety protecting to protect when:

• Over discharge• Over charging • Over temperature

• Monitoring system to determine the condition of the battery pack

• High domestic content level

DEVELOPMENT OF BATTERY & BMS

IVC and Display meter • Using the CAN platform• Display information for the driver regarding

performance including:• Speed display• RPM• Battery status

• IVC models and IoT-based meter displays:• Information on performance• Service requirements • Maintenance planning

• Energy monitoring system with variations for road mode

• Synchronize with google maps• Equipped with monitoring and maintenance• High domestic content level

DEVELOPMENT OF IVC

• Performance Testing Equipment for Motorcylce and Vehicle

• Composite Fabrication

• 3D Scanner and 3D Photogravimetry

• Product Prototyping

• Engineering Design and Reverse Engineering

• Controller Development Suites and Prototyping

• BLDC Motor Design, Prototyping, and Testing

• Electric Motorcycle Assembly Line

FASILITAS R & D FACILITIES DI STP OTOMOTIF ITS

Nama Alat: TRACTUS 3DFungsi: Untuk membuat prototype

dalam bentuk 3D printing

Nama Alat: DYNO TESTFungsi: untuk menguji

performa mesin

Nama Alat: CNC BUBUTFungsi: untuk membuat

benda kerja secaraotomatis

Nama Alat: CNC MillingFungsi: untuk membuatbenda kerja secaraotomatis

DEVELOPMENT MOTORCYCLE

TERIMA KASIHSEMOGA BERMANFAAT