Table Of ContentThe Science of Electric
Vehicles
The Science of Electric Vehicles: Concepts and Applications presents the basic elec-
trical principles, physics, chemistry, use of rare earth elements (REEs), batteries,
charging, and operation of motor controllers of EVs. In addition to the general con-
cepts, the book examines the policies and economics pertinent to the move from
hydrocarbon power to electric-powered vehicles. It covers the history and develop-
ment of electric vehicles as well as the science and engineering behind them.
Features:
• Presents the basic electrical principles, physics, and chemistry involved in
the manufacture of electric vehicles.
• Discusses various battery types, energy efficiency, storage, and more.
The Science of Electric
Vehicles
Concepts and Applications
Frank R. Spellman
Designed cover image: Shutterstock | Gorodenkoff
First edition published 2023
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742
and by CRC Press
4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
CRC Press is an imprint of Taylor & Francis Group, LLC
© 2023 Taylor & Francis Group, LLC
Reasonable efforts have been made to publish reliable data and information, but the author and pub-
lisher cannot assume responsibility for the validity of all materials or the consequences of their use.
The authors and publishers have attempted to trace the copyright holders of all material reproduced
in this publication and apologize to copyright holders if permission to publish in this form has not
been obtained. If any copyright material has not been acknowledged please write and let us know so
we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced,
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known
or hereafter invented, including photocopying, microfilming, and recording, or in any information
storage or retrieval system, without written permission from the publishers.
For permission to photocopy or use material electronically from this work, access www.copyright.
com or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA
01923, 978-750-8400. For works that are not available on CCC please contact mpkbookspermis-
[email protected]
Trademark notice: Product or corporate names may be trademarks or registered trademarks and are
used only for identification and explanation without intent to infringe.
Library of Congress Cataloging‑in‑Publication Data
Names: Spellman, Frank R., author.
Title: The science of electric vehicles : concepts and applications / Frank
R. Spellman.
Description: First edition. | Boca Raton : CRC Press, 2023. | Includes
bibliographical references and index. |
Identifiers: LCCN 2022044179 (print) | LCCN 2022044180 (ebook) |
ISBN 9781032366289 (hardback) | ISBN 9781032366296 (paperback) |
ISBN 9781003332992 (ebook)
Subjects: LCSH: Electric vehicles.
Classification: LCC TL220 .S647 2023 (print) | LCC TL220 (ebook) |
DDC 629.22/93–dc23/eng/20221206
LC record available at https://lccn.loc.gov/2022044179
LC ebook record available at https://lccn.loc.gov/2022044180
ISBN: 978-1-032-36628-9 (hbk)
ISBN: 978-1-032-36629-6 (pbk)
ISBN: 978-1-003-33299-2 (ebk)
DOI: 10.1201/9781003332992
Typeset in Times
by codeMantra
Contents
List of Acronyms and Abbreviations ........................................................................xi
Preface......................................................................................................................xv
Author ....................................................................................................................xvii
Chapter 1 Electric Vehicles (EVs) .........................................................................1
Introduction ..........................................................................................1
Chapter 2 Electron Flow = Traffic Flow ...............................................................3
Back in the Good Old Days ..................................................................3
How Times Have Changed ...................................................................3
Chapter 3 Basic Electricity ...................................................................................7
Introduction ..........................................................................................7
Nature of Electricity .............................................................................7
The Structure of Matter ...................................................................8
Conductors .........................................................................................11
Unit Size of Conductors .................................................................11
Square Mil .....................................................................................12
Circular Mil ...................................................................................12
Circular-Mil-Foot ..........................................................................14
Resistivity ......................................................................................14
Wire Measurement ........................................................................16
Factors Governing Selection of Wire Size ....................................16
Copper vs. Other Metal Conductors ..............................................18
Temperature Coefficient (Wire).....................................................18
Conductor Insulation .....................................................................20
Conductor Splices and Terminal Connections ..............................20
Soldering Operations .....................................................................20
Solderless Connectors ....................................................................21
Insulation Tape ..............................................................................21
Static Electricity ............................................................................21
Charged Bodies .............................................................................22
Coulomb’s Law ..............................................................................22
Electrostatic Fields ........................................................................23
Magnetism .....................................................................................24
Magnetic Materials ........................................................................25
Magnetic Earth ..............................................................................26
Difference in Potential...................................................................27
Water Analogy ...............................................................................28
Principal Methods of Producing a Voltage....................................29
v
vi Contents
Electric Current .............................................................................31
Resistance ......................................................................................32
Electromagnetism ...............................................................................33
Magnetic Field Around a Single Conductor ..................................34
Polarity of a Single Conductor ......................................................35
Field Around Two Parallel Conductors .........................................35
Magnetic Field of a Coil ................................................................36
Polarity of an Electromagnetic Coil ..............................................37
Strength of an Electromagnetic Field ............................................37
Magnetic Units ..............................................................................38
Properties of Magnetic Materials ..................................................39
Permeability ..............................................................................39
Hysteresis ..................................................................................39
Electromagnets ..............................................................................40
One More Word ..................................................................................40
Chapter 4 Battery-Supplied Electricity ...............................................................41
Basic Battery Terminology .................................................................41
Battery Characteristics .......................................................................42
Voltaic Cell .........................................................................................43
Primary and Secondary Cells .............................................................44
Battery ................................................................................................45
Battery Operation ...............................................................................45
Combining Cells .................................................................................46
Types of Batteries ...............................................................................47
Electric Vehicle Terminology .............................................................50
One More Word ..................................................................................51
Reference ............................................................................................51
Chapter 5 AC Theory ..........................................................................................53
Introduction ........................................................................................53
Basic AC Theory and Principles .........................................................53
Basic AC Generator .......................................................................55
Cycle ..............................................................................................55
Frequency, Period, and Wavelength ..............................................57
Characteristic Values of AC Voltage and Current ...............................58
Peak Amplitude .............................................................................58
Peak-to-Peak Amplitude ................................................................58
Instantaneous Amplitude ...............................................................59
Effective or RMS Value ................................................................59
Average Value ................................................................................60
Resistance in AC Circuits ..............................................................61
Phase Relationships .......................................................................63
Inductance .....................................................................................64
Inductance: What Is It? ..................................................................64
Unit of Inductance .........................................................................65
Contents vii
Self-Inductance ..............................................................................66
Growth and Decay of Current in an RL Series Circuit .................68
Mutual Inductance .........................................................................69
Calculation of Total Inductance ....................................................70
Capacitance ...................................................................................71
The Capacitor ................................................................................71
Dielectric Materials .......................................................................73
Unit of Capacitance .......................................................................75
Factors Affecting the Value of Capacitance ..................................76
Voltage Rating of Capacitors .........................................................77
Charge and Discharge of an RC Series Circuit .............................78
RC Time Constant .........................................................................79
Capacitors in Series and Parallel ...................................................79
Types of Capacitors .......................................................................81
Ultracapacitors ...............................................................................82
Ultracapacitor Operation ...............................................................82
Inductive and Capacitive Reactance ...................................................83
Inductive Reactance .......................................................................83
Capacitive Reactance .....................................................................86
Phase Relationship of R, L, and C Circuits ...................................87
Impedance .....................................................................................88
Power in Reactive Circuits ............................................................89
Series RLC Circuit ........................................................................89
Parallel RLC Circuits ....................................................................91
Power in AC Circuits .....................................................................92
Reference ............................................................................................94
Chapter 6 Fundamental Physics Concepts ..........................................................95
Introduction ........................................................................................95
Resolution of Forces ...........................................................................96
Slings .............................................................................................99
Inclined Plane ...............................................................................102
Properties of Materials and Principles of Mechanics .......................105
Properties of Materials .................................................................105
Friction .........................................................................................110
Pressure ........................................................................................110
Specific Gravity ............................................................................110
Force, Mass, and Acceleration .....................................................111
Centrifugal and Centripetal Forces ..............................................111
Stress and Strain ...........................................................................112
Principles of Mechanics ...................................................................112
Statics ...........................................................................................112
Welds ............................................................................................113
Dynamics ......................................................................................113
Hydraulics and Pneumatics—Fluid Mechanics ...........................113
References ........................................................................................113
viii Contents
Chapter 7 Dynamics of Vehicle Motion ............................................................115
Factors Affecting Vehicle Dynamics ................................................115
Vehicle-on-Wheels Layout ...........................................................116
Powertrain ....................................................................................116
Braking System ............................................................................116
Geometry of Suspension, Steering, and Tires ..............................116
Pure Dynamics .............................................................................119
Aerodynamics ...................................................................................119
Weight ...........................................................................................120
Lift ................................................................................................120
Drag ..............................................................................................120
Thrust ...........................................................................................121
Rolling Resistance .......................................................................122
Hill Climbing ..............................................................................123
Linear Acceleration .....................................................................123
Angular Acceleration ..................................................................124
Tractive Force ..............................................................................124
References ........................................................................................124
Chapter 8 Electric Motors .................................................................................125
Motors ..............................................................................................125
DC Motors ........................................................................................126
AC Motors ........................................................................................128
Induction Motors .........................................................................128
Synchronous Motors ....................................................................129
Single-Phase Motors ....................................................................130
Split-Phase Motors .......................................................................130
Capacitor Motors .........................................................................131
Shaded-Pole Motor .................................................................131
Repulsion-Start Motor .................................................................132
Series Motor ................................................................................132
Internal Permanent Magnet (IPM) Motors .................................133
Switched Reluctance Motors (SRM) ...........................................133
Chapter 9 DC/DC Converters ...........................................................................135
Introduction ......................................................................................135
Terminology and Definitions .......................................................135
Non-isolated and Isolated Converter Topologies
(aka Configurations) ....................................................................137
Reference ..........................................................................................138
Chapter 10 Inverters ............................................................................................139
The 411 on Electric Vehicles Inverters .............................................139
Electric Vehicles—Present and Future........................................140
Contents ix
Chapter 11 EV’s Carburetor .................................................................................143
Introduction ......................................................................................143
Controllers ........................................................................................144
Controller Components/Elements ................................................144
Resistors ...................................................................................145
Inductors ..................................................................................146
Capacitors ................................................................................149
Supercapacitors: The Need ......................................................153
Diodes: The One-Way Valves ..................................................154
Transistors ................................................................................154
A Change of State.............................................................................155
DC Controllers..............................................................................156
The Bottom Line ..............................................................................157
References ........................................................................................157
Chapter 12 Regenerative Braking and More.......................................................159
Slowing and Stopping ......................................................................159
The 411 on Regenerative Braking ....................................................159
How Does Regenerative Braking Work? .....................................159
Efficiency Comparison and Contrast ...........................................161
The Bottom Line ..............................................................................161
Chapter 13 Battery Power Alternatives ..............................................................163
Introduction ......................................................................................163
Fuel Cells ..........................................................................................163
Key Terms....................................................................................164
Hydrogen Fuel Cells and Other Types .............................................170
Hydrogen Storage ........................................................................173
How a Hydrogen Fuel Cell Works ...............................................174
Other Types of Fuel Cells .................................................................175
Direct Methanol Fuel Cells .........................................................175
Alkaline Fuel Cells ......................................................................176
Phosphoric Acid Fuel Cells .........................................................176
Molten Carbonate Fuel Cells .......................................................177
Solid Oxide Fuel Cells .................................................................177
Reversible Fuel Cells ...................................................................178
Polymer Electrolyte Membrane Fuel Cells (PEM) .....................178
Parts of a PEM Fuel Cell .............................................................179
Membrane Electrode Assembly ..............................................179
Polymer Electrolyte Membrane ..............................................179
Catalyst Layers .......................................................................180
Gas Diffusion Layers (GDLs) .................................................180
Hardware Components ................................................................180
Bipolar Plates ..........................................................................180
Gaskets .....................................................................................181
