Eventos Anais de eventos
COBEM 2021
26th International Congress of Mechanical Engineering
Tecnomobelet – Adaption of Van for electric propulsion and design of steering, cooling and braking assistance subsystems
Submission Author:
SALEH KHALIL , DF
Co-Authors:
SALEH KHALIL, Rudi van Els, João Wohlgemuth, Danilo dos Santos Oliveira, Gabriel Chules, João Gabriel Paulino de Souza, Pedro Augusto Andrade Rodrigues, Maria Eduarda Borges Galvão
Presenter: João Wohlgemuth
doi://10.26678/ABCM.COBEM2021.COB2021-1133
Abstract
The current need of reducing toxic emissions gases in the transport sector leads to the necessary electrification of transport and development of technology for electric mobility. This motivated a multidisciplinary group, from the Faculty of Engineering of the University of Brasilia Gama Campus, to start a project to convert a Peugeot Boxer Van with a 2.8L diesel motor to electric propulsion. The project started with the survey of all the parts that could be removed and adapted from the vehicle, in order to install the electric motor and its control system in the original engine compartment. The diesel engine was replaced by a water-cooled three-phase 60kW induction motor from WEG, with its necessary control driver. The challenge of the project is the design of the necessary couplings and supports to install the electric motor as well as the design of a new brake assistance subsystem, a new steering assistance subsystem and a new cooling subsystem for the water-cooled electric motor and driver because all the original subsystems were driven by the mechanical power of the diesel motor. In order to dimension the mechanical resistance of the coupling, fixing and attachment elements, a simulation was made with Ansys program and as a result, a flange to fix the electric motor to the transmission, a sleeve of rigid coupling to connect the motor to the transmission, and support for fixing the motor were designed. The cooling subsystem with the replacement of the original pump by an electric pump was be preceded by the thermodynamic calculation of the performance of the coolant flow. The original brake subsystem was replaced by an electrical driven vacuum pump servo system, connected to the original hydraulic brake. The hydraulic steering subsystem driven by a hydraulic pump was replaced by an electrically-assisted steering system. The electric motor cooling subsystem was designed using the original radiator with an appropriate flow driven by an electric water pump for circulation. The design of these subsystems for the mechanical transformation were finalized and the next phase will be to test the Van on a (roller) chassis dynamometer, before the dynamic road test.
Keywords
Automotive Electric Motor, manufacturing process, Conversion of low-cost Combustion Engine to Electric, Steering Subsystem, Brake Subsystem;
