DACIA_Electra

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Research Regarding the Development of an

Electric Vehicle

Danut Gabriel MarinescuFaculty of Mechanics and Technology, Automotive Department

University of Pitesti, 1, Targu din Vale street, 110040, Pitesti, Romania

E-mail: [email protected]

Ion Tabacu

Faculty of Mechanics and Technology, Automotive DepartmentUniversity of Pitesti, 1, Targu din Vale street, 110040, Pitesti, Romania


Stefan TabacuFaculty of Mechanics and Technology, Automotive Department

University of Pitesti, 1, Targu din Vale street, 110040, Pitesti, Romania


Cornel NaeMilitary School Basarab I ,Trivale street , 16 , Pitesti, Romania

E-mail: :[email protected]

Copyright 2009 MC2D & MITI

Abstract: This paper presents aspects regarding the research starting in 2008 within the project ECO

EV for realization an experimental flexible platform of ecologic electric vehicle. The electric system

type, developed as part of the EcoMatic Hybrid System is assembled on a newly experimental vehicle,

DACIA Electra based on a Dacia Logan in the Automotive Engineering Research Centre of theUniversity of Pitesti.

Keywords: Passenger car,Ecologic Vehicle, Electric Vehicle

1. IntroductionConsidering the world wide approach intransportation to reduce the petrol dependence,

save and preserve energy a process of

developing the ECO EV (ECOlogic ElectricVehicle) is in progress within the AutomotiveEngineering Research Centre of the University

of Pitesti.

It is part a of ECOlogic Program strategy(Figure 1) foreseen to take place during 2009-

2011 period, in Alternative Propulsion System

& Renewable Energies laboratory a part of theAutomotive Engineering Research Centre of

University of Pitesti.

Addressing this theme was influenced by therevival in particular of the electric vehicle as aresult of technological developments in

lithium-ion battery and low price of electricity

transport [1].The concept car, first time presented in this

paper, was developed based on the mechanical

March 26-29


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platform of Dacia Logan and is underconstruction thanks to a financial aid granted

by the Romanian Ministry of Education,

Research and Innovation [2] and the technicalhelp of the Dacia Group Renault that has the

plant near Pitesti.

2. Car body and ECO EVarchitectureThe cars body was built based Dacia LoganECO HYBRID, 2008 version [2] equipped whit EcoMatic Hybrid System (Energy conversion

with autoMaticHybrid System) [3].Unlike the model of the DACIA Logan fromwhich was started the new vehicle body was

changed in the rear side (Figure 2).

This change will be followed the enlargement

of the roof area to be covered withphotovoltaic cells and vehicle customization.

For the body works and to implement newcomponents, a measuring arm ROMER

SIGMA 2018 was used. (Figure 3).

This allows numerical digitisation of the

surfaces using PC-DMIS software withCATIA V5 import/export option available, and

also for the verification of the final

construction according to the CAD data.Also required spaces for vehicles sub

assemblies can be checked in order to ensurethe proper mounting conditions.

Gaps and clearance between the working parts,vehicle structure and onboard systems are

verified and validated for good operating

conditions.Bodywork can allow the implementation ofthree architectures for Eco EVelectric drive

train system: front wheel drive, rear wheeldrive, (similarly Dacia Logan ECO HYBRID

E-4WD) and in 4x4 electric variant.

For this stage the front wheel drivearchitecture was chosen (Figure 4).

3. The electric propulsion equipmentsystem construction

The electric propulsion equipment system was

taken over mainly from Logan ECO HYBRID

E-4WD [2].

Figure 2: The DACIA Electra underconstruction in the Automotive

Engineering Research Centre of theUniversity of Pitesti

Figure 3: The measuring arm ROMER

SIGMA for numerical digitization of the

surfacesDACIA Electra

Figure 1:ECOlogic Program strategy for 2009-2011 period in the Alternative PropulsionSystems & Renewable Energies laboratory,Automotive Engineering Research Centre


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In DACIA Electras case, it was placed at thefront side of vehicle (Figure 5).

It consists in the motor asynchronous type and

the mechanical transmission, used to adapt the

energetic and kinematics parameters of themotor to the driving conditions and it also

provides the mechanical energy to the frontwheels.The motor assigned is made by MES-DEA

Swiss, asynchronous type, 16 kW (22 hp) of

continuous power, 60 Nm @ 2850 rpm, fluidcooled. The control of the electric motor is

also made by MES-DEA Swiss. TIM

(Traction Inverter Module) is a vector control

AC motor drive, especially designed forelectric and hybrid vehicles [5].

All the driving commands (accelerator pedaland selector RND/P lever) are drive by wirecommands.

The ELECTRA transmission is manufacturedas a prototype starting fromDacia mechanical

elements and consists in the reduction unit-differential assembly mounted in a common

case made by light alloy and the shafts, whichtransmits the electric power to the frontwheels.

The reduction unit-differential assembly was

designed to have only one gear ratio. On the

other hand, in order to have flexibility to themounting of a standard electric motor and tooffset it from the shaft of the final drive, we

decided to use the three shafts transmission:

the primary shaft, the intermediary shaft andthe secondary shaft (the shaft of differential).

All shafts are in the same plane. The gear

wheels feature helical gears.For the Parking mode a locking mechanism

actuated electromechanically by pressingbutton P of the selector lever was designed.The differential, in a classical design, is

integrated into the gear reduction unit in a

common case manufactured by light alloy.The final drive shafts make the connectionbetween the gear reduction unit - differential

assembly (mounted pseudo-elastic on vehicles

body) and the front wheels.For economic considerations final drive shafts,

the transmission case, gear wheels thedifferential and the suspension of the power

train areDACIA Logan components.

The electric equipments needed for electricenergy generating/storing/plug-in to the home

electric network include a traction battery,lithium-ion technology, an embarked AC/DC

charger and a DC/DC converter for converthigh voltage to 12 Volts for storing in theauxiliary battery.

This equipment is completed by an assembly

of photovoltaic cell placed on the roof. At first

this is connected only to the low voltage circuit(12V) which supplies the auxiliarypreconditioning outfit of the vehicle interior.

All these equipments will be purchased in the

period immediately following the finalizationthe model vehicle complete and performance

simulation software AVL Cruise.

4. Specific auxiliary systemsIn order to maintain the driving comfort thehydraulic system used to assist the steering

available on Dacia Logan Diesel (1,5 dci),

system with electrical pump group, wasadapted.

To enhance maneuverability (for vehicle

parking) a version of a rear axle with steer able

wheels actuated electro-mechanical is underconstruction.

To maintain the braking comfort a vacuumelectro-pump specially manufactured for EVswas used.

To provide the thermal comfort in the cockpit

a climatic group which is compatible with theelectric propulsion system will allow the

Figure 4. Architecture of the DACIA Electra with

EcoEV System: 1 Electric Motor; 2 TractionInverter Module (Motor control); 3 Transmission

Traction Battery Module; 4 Transmission; 5 Battery

Charger; 6 DC/DC converter for starting battery; 7Starting battery, 8 solar panel; 9 DC/DC solar panel

converter

Figure 5: TheDACIA Electra power trainimplementation on the front side ofvehicle (power train in construction)


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rationalization of the electric energy

consumption by contribution of the:

Thermal energy from the cooling system ofthe electric equipment components (motor,

traction battery etc) when heating the

passenger cockpit is required;

Solar energy from the photovoltaic cellspanel placed on the roof will provide airconditioning in the vehicle interior.

To reduce consumption of electricity to if

the lighting lamps, the incandescent lightbulbs, were replaced with LED's (Figure 6).

5. Modeling and simulationTo simulate the driving and consumptionperformances of DACIA Electra, CRUISE

software, recently received from the AVL, was

used.Its modular concept enables free modeling ofall possible vehicle configurations while

sophisticated solvers guarantee short

calculation times [6].

CRUISE is typically used in drive train and

engine or motor development to calculate andoptimize the following: Fuel Consumption and Emissions;

Driving Performance (acceleration,

elasticity); Transmission Ratios;

Braking performance,

and for the determination of: Collective Loads for Stress Calculations;

Drive train Vibrations.The modular structure of CRUISE permitsmodeling of all existing and future vehicle

concepts for both single and double track

vehicles (motorcycles, passenger cars, trucks,etc.).

6. The experimental research baseIn order to perform the tests of the alternative

vehicles (EVs, HEVs) or propulsion systemfor automobiles fueled by alternative and

renewable energies at the Automotive

Engineering Research Centre of University ofPitesti a new laboratory is under construction.

It has:

An Schenk roller test bench adapted fortesting the electric and hybrid electric vehicle;

An Hoffmann Eddy-current engine/motorbrake for testing the performances of engines,

motors and hybrid power train systems.In order to test theDACIA Electra andDACIAECO Hybrid prototypes on dynamometric

chassis they are placed in a specific

architecture (Figure 8)

The false axle mounted on the bench in a

parallel with the front axle of the vehicle is

used to evaluate the recuperative braking

attempts capacity of theLogan ECO-Hybrid E-

Figure 6: The DACIA Electra

lighting systems utilize the lampswhit LEDs components

Figure 7: The CRUISE software from AVLusing for modeling DACIA Electra and

simulating driving performance and energyconsumption

Figure 8: The test bench for electric and hybridelectric vehicle under construction in theAlternativePropulsion System & Renewable Energies

laboratory , Automotive Engineering Research

Centre, University of Pitesti


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4WD [4] by a power train simulator with

thermal engine.In such a configuration, on the rollerbenchmark, tests will be performed in order to

simulate either the standard driving cycles or

other types of cycles.In order to test the prototype on the road for

measuring the dynamic performances of the

vehicle, within longitudinal movement, therehas been necessary to accomplish an assembly

of specific equipments.It consists of a DATRON CORREVITequipment (Figure 9) with optical sensor and a

personal computer - onboard vibration

resistant - dedicated to be used for dataacquisition system DAQ USB-30A16 andspecific sensors.

The non-contact, optical sensor systems made

by CORRSYS-DATRON provide a superior

solution for the measurement of speed,distance, and other dynamic measurement

variables.The operation of the system is visualized by

the driver in real time on a 7 color andmultitasking display.

7. ConclusionThe ECO EV( ECOlogic Electric Vehicle)project in development in the new Alternative

Propulsion System & Renewable Energies

laboratory part of Automotive EngineeringResearch Centre, University of Pitesti is an

experimental platform for research electric

propulsion system for the urban automobiles.

The vehicle realized in this project on the

mechanical platform of Dacia Logan is anDACIA ECO

3vehicle:

ECOlogic due to ZEV propulsion system; ECOnomic because is based on the lessexpensive commercially available version of

DACIA Logan;

ECOnomic due to the low price of theelectricity used to charge the on board storagedevices.

The experimental platform ECO EVisdesigned also for developing new ecologicalprojects by implementing other new

equipments: range extender (fuelling by

GPL/NGV), in first step and a fuel cell in thefuture.

The research laboratory with an dynamometric

testing roller benchmark, engine benchmarkand road testing equipments, will allow thedevelopment of future projects regarding the

ecological propulsion of the vehicles and the

extension of the cooperation with otherinterested team, having similar research

objectives.

Acknowledgement

This work was financially supported by RomanianMinistry of Education, Research and Innovation was

performed with the technical help of AutomobileDacia Group Renault, MES-DEA and AVL for

whom we express our gratitude.

References

[1] Perrin, J., Towards the massive

deployment of electric cars,4th

European

Conference on Alternative Energies for

the Automotive Industry. Futuroscope-

Poitier, France, April 2-3, 2008.[2] Marinescu, D., G., An Experimental

Ecological vehicle featuring hybridPropulsion System of Liquefied Petroleum

Gas (LPG)- Electricity type, Grant

CNCSIS A956, financed by Ministry ofEducation and Research, Final report,

2007.[3] Marinescu, D.G., Clenci, A., Tabacu, S.,

A Plug-in Hybrid Electric Vehicle,Third

International Conference on Ecological

Vehicles & Renewable Energies, EVERMonaco 2008, March 27-30.

[4] Marinescu, D.G., Tabacu, I., Serban

F.,Clenci A., Tabacu, S., Serban F, Plug-in Hybrid Electric Vehicle E- 4WD type, 4th European Conference on Alternative

Energies for the Automotive Industry.Futuroscope- Poitier, France, April 2-3,

2008.[5] MES-DEA Documentation

[6] AVL Documentation

Figure 9: The DATRON CORREVIT

equipment for measuring the dynamic

performances of the vehicle on the road

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