"v© 2024 SAE InternationalPreface xviiAcknowledgments xviiiList of Acronyms xixC H A P T E R 1Dynamic Performance 11.1. Indicators of Dynamic Performance 11.2. Tractive Effort and Resistance Forces 21.2.1.Tractive Effort 21.

2.2. Resistance Forces 61.3. Vehicle Dynamic Equation 171.3.1. Equilibrium Diagrams of Driving Force and Running Resistance 181.

3.2. Acceleration Capacity 191.3.3. Gradeability 201.4. Tire-Ground Adhesion 201.

4.1. Adhesion Coefficient and Adhesion Condition 201.4.2. Adhesion Coefficient 211.4.3.

Adhesion-Related Forces 211.4.4. Minimal Adhesion Coefficient Requirements 241.5. Equilibrium of Power 261.6. Dynamic Performance Tests 281.

6.1.Road Tests 281.6.2. Rig Tests 29References 29ContentsContentsviC H A P T E R 2Energy Economy 312.1. Indicators of Energy Economy 312.

2. Estimation of Energy Economy 362.3. Factors Impacting Energy Economy 372.3.1. Reduction in Vehicle Weight and Size 422.3.

2. Electric Motor System 432.3.3. Drivetrain 432.3.4. Body Aerodynamics 432.

3.5. Tire 442.3.6. Thermal Management 442.4. Energy Economy Testing 45References 46C H A P T E R 3Selection of Dynamic Parameters 473.

1. Selection of Electric Motor Power 473.2. Selection of the Smallest Speed Ratio 493.3. Selection of the Largest Speed Ratio 503.4. Selection of the Number of Gears and Intermediate SpeedRatios 513.

5. Determination of Transmission and Final Drive Ratios 543.5.1. Determination of the Final Drive Ratio 543.5.2. Optimization of Speed Ratios 55References 58C H A P T E R 4Braking Performance and Energy Regeneration 614.

1. Evaluation Indicators for Braking Performance 614.2. Wheel Force Analysis during Braking 624.2.1. Ground Braking Force 634.2.

2. Braking Force at the Tire Circumference 634.2.3. Relationship between Adhesion and Braking Forces 644.2.4. Adhesion Coefficient on Hard-Surface Roads 64Contents vii4.

3. Braking Efficiency and Constancy 684.3.1. Stopping Distance and Deceleration 684.3.2. Analysis of Stopping Distance 694.

3.3. Constancy of Braking Efficiency 704.4. Directional Stability in Braking 714.4.1.Braking Deviation 714.

4.2. Sideways Skid and Loss of Steering in Braking 724.5. Front and Rear Proportioning of a Braking Force 744.5.1. Normal Reaction Forces from the Ground to Front andRear Wheels 754.

5.2. Ideal Curve of Front and Rear Braking Force Proportioning 764.5.3. Fixed Proportioning of Front and Rear Brake Forces 774.5.4.

Analysis of the Braking Process of EVs with Fixed BrakeProportioning 784.5.5. Adhesion Utilization and Braking Efficiency 814.5.6. Requirements for Brake Proportioning 834.5.

7. ABS 844.6. Braking Performance Tests 864.6.1.Road Tests 864.6.

2. Rig Tests 884.7. Regenerative Braking 884.7.1. Mechanical and Electrical Compound Braking 894.7.

2. Brake Proportioning for Maximization of Regenerative Energy 91References 95C H A P T E R 5Handling and Stability 975.1. Cornering Characteristics of Tires 975.1.1.Coordinate System 975.1.

2. Lateral Forces in Cornering 995.1.3. Factors Affecting Cornering Behavior 1005.1.4. Aligning Torque 1015.

1.5. Behavior of a Tire with the Camber Angle 1025.2. Vehicle Response to the Input of the Front Wheel Angle 1045.3. Steady-State Response to the Input of the FrontWheel Angle 1065.3.

1. Yaw Velocity Gain 1065.3.2. Ratio of Turning Radii 1085.3.3. Static Margin 1095.

3.4. Difference in Sideslip Angles 110Contentsviii5.4. Instantaneous Response to the Step Input of the FrontWheel Angle 1115.4.1. Equation of Motion and Its Solution 1115.

4.2. Stability Conditions of Instantaneous Response 1155.5. Yaw Rate Frequency Response Characteristics 1165.6. Suspension Effects on Handling Stability 1175.6.

1. Suspension-Related Cornering Behavior 1185.6.2. Roll Steer 1265.6.3. Compliance Steer Related to Lateral Force 1275.

6.4. Compliance Steer Related to Aligning Torque 1285.6.5. Compliance Camber Change 1295.7. Steering System Effect on Handling 1295.

7.1. Functionality of the Steering System 1295.7.2. Fundamental Handling Characteristics 1325.7.3.

Steering Effort Characteristics 1325.7.4. On-Center Handling Characteristics 1335.7.5. Movement Interference between the Steering System andSuspension during Body Roll 1355.7.

6. Compliance Steer Related to Steering System Stiffness 1355.8. Drivetrain System Effect on Handling 1355.8.1. Mechanisms of the Tractive Force Effect on CorneringCharacteristics 1355.8.

2. Cornering Stability Control by Tractive and Braking Forces 1375.8.3. Electronic Control Systems for Handling Stability 1395.9. Rollover 1435.9.

1. Quasistatic Rollover Analysis of a Rigid Vehicle 1435.9.2. Quasistatic Rollover Analysis of a Vehicle with Suspension 1455.9.3. Transient Rollover Analysis 1465.

10. Vehicle Handling Tests 1475.10.1. Low-Speed Steering Effort Tests 1475.10.2. Steady-State Steering Characteristics Tests 1485.

10.3. Transient Yaw Response Tests 1485.10.4. Self-Aligning Tests 1495.10.5.

Pulse Steering Tests 1495.10.6. On-Center Handling Tests 149References 149Contents ixC H A P T E R 6Ride Comfort 1516.1. Excitation Sources 1526.1.1.

Electric Motors 1526.1.2. Drivetrain 1556.1.3. Wheels and Tires 1576.1.

4. Road Roughness 1616.2. Vehicle Response to Excitations 1656.2.1. Dynamic Model of a Vehicle 1656.2.

2. Fundamental Behavior of Sprung Mass 1686.2.3. Frequency Response to Road Excitation 1696.2.4. Statistical Characteristics of System Response 1716.

3. Effects of System Parameters on Vibration Response 1796.4. Human Perception of Vibrations 1796.5. Evaluation of Ride Quality 1806.5.1.

Basic Evaluation Method 1806.5.2. Alternative Evaluation Method 1816.5.3. Sound Quality Evaluation 181References 183C H A P T E R 7Trafficability 1857.1.

Indices and Geometric Parameters for TrafficabilityEvaluation 1857.1.1. Indices for Trafficability Evaluation Related to GroundBearing Capacity 1857.1.2. Structural and Geometric Parameters Related toTrafficability 1867.2.

Physical Properties of Soft Ground 1887.2.1. Relationship between Shear Stress and Shear Deformationin Soft Ground 1887.2.2. Relationship between Subsidence and Vertical Loads 1907.2.

3. Effect of the Density of Semifluid Mud and Snow onTrafficability 1917.3. Drawbar Pull of EVs 1917.3.1. Traction Force Acting on the Vehicle from Soft Ground 1927.3.

2. Resistance on the Vehicle Traveling on Soft Ground 1937.3.3. Calculation of the Drawbar Pull 197Contentsx7.4. Tractive Trafficability 1977.5.

Conditions for Obstacle Clearance 2007.5.1. Obstacle Clearance of the Front End 2007.5.2. Obstacle Clearance of the Underbody 2017.6.

Overcoming Terrain Steps and Trenches 2027.6.1. FWD Vehicle Overcoming Steps 2027.6.2. RWD Vehicle Overcoming Steps 2047.6.

3. AWD Vehicle Overcoming Steps 2067.6.4. Evaluation of Trench Obstacle Capability 2087.7. Testing of Trafficability 2087.7.

1. Brief Descriptions of Trafficability Tests 2087.7.2. Measurements of Soil Parameters 209References 210C H A P T E R 8Vehicle-Level Design 2118.1. Categorization and Classification of EVs 2118.1.

1. Classification of Electric Cars 2118.1.2. Classification of Electric Buses 2128.1.3. Classification of Trucks 2128.

2. Body Style 2128.2.1. Body Styles of Cars 2128.2.2. Body Styles of Buses 2178.

2.3. Body Styles of Trucks 2188.3. Electric Drive System Layout 2208.3.1. Number of Axles and Axle Load 2208.

3.2. Basic Principles of Electric Drive System Layout 2218.4. Selection of Overall Design Parameters 2238.4.1. Dimensional Parameters 2238.

4.2. Mass-Related Parameters 2268.4.3. Performance-Related Parameters 2288.5. Selection of Battery System 2318.

5.1. Battery Type Selection 2318.5.2. Selection of Battery System Parameters 2328.5.3.

Packing of the Battery System 234Contents xi8.6. Selection of Electric Drive Systems 2368.6.1. Electric Motor Selection 2368.6.2.

Selection of Electric Drive System Parameters 2408.6.3. Electric Drive System Mounts 2448.7. Selection of Suspensions 2458.7.1.

Front Suspension 2458.7.2. Rear Suspension 2468.8. Selection of Tires 2478.9. Overall Vehicle Layout Design 2478.

9.1. Battery System Layout 2488.9.2. Powertrain System Layout 2498.9.3.

Steering System Layout 2528.9.4. Layout of Suspensions 2528.9.5. Brake System Layout 2538.9.

6. Layout of Operator Pedals 2538.9.7. Layout of Luggage Space and the Spare Tire 2548.9.8. Vehicle Interior Layout 2548.

9.9. Sizing of Vehicle Body 2568.9.10. Mounting Positions of Seat Belts and Airbags 2578.10. Motion Correctness Check 258References 258C H A P T E R 9Battery System Design 2599.

1. Types of Battery Cells 2609.2. Battery Pack Architecture 2619.3. Electrical Topology of Battery Packs 2629.3.1.

Battery Cells Connected in Series 2629.3.2. Battery Cells Connected in Parallel 2639.3.3. Battery Cells Connected in Series-Parallel 2649.3.

4. Guidelines for the Design of Pack Topology 2659.4. Design of Battery Packs 2679.4.1. Structural Design of Battery Packs 2679.4.

2. Design of a BTMS 2739.4.3. Design of a BMS 276References 285ContentsxiiC H A P T E R 1 0Electric Drive System Design 28710.1. Electric Drive System Configurations 28810.2.

Design of Electric Motors 28910.2.1. Topology of Electric Motors 28910.2.2. Basic Design Parameters and Equations 29010.2.

3. Sizing of Electric Motors 29510.2.4. Design of a Magnetic Circuit 30210.2.5. Electromagnetic Design 31110.

2.6. Losses, Temperature Rise, and Cooling 32910.2.7. Design Guidelines for PMSMs 34210.3. Design of Electric Motor Controllers 35410.

3.1. Design of Main Control Boards 35510.3.2. Design of Driver Boards 35710.3.3.

Design of High-Voltage Main Circuits 35910.3.4. Design Guidelines for SiC Motor Controllers 36010.4. Design of Drivetrains 37410.4.1.

General Layout Design 37910.4.2. Determination of Basic Characteristic Parameters 38010.4.3. Design of Layshaft Gearsets 38110.4.

4. Design of Planetary Gearsets 39110.4.5. Design of Clutches 41010.4.6. Design of Synchronizers 41610.

4.7. Design of Shift Actuators 42310.4.8. Design of Hydraulic and Lubrication Systems 43210.4.9.

Design of Housing 442References 448C H A P T E R 1 1Suspension System Design 45311.1. Types of Vehicle Suspension System 45411.1.1. Types of.