EV Electrical Systems BASICS!

Summary

The video explores the exciting shift towards electric vehicle (EV) electrification, emphasizing its impact on motorsports and performance cars. It breaks down the complexities of EV electrical systems into three main subsystems: high voltage, low voltage, and CAN networks. Key components like battery packs, inverters, and power distribution units are discussed, highlighting their roles in vehicle performance and safety. The integration of these systems enables enthusiasts to enjoy tailored driving experiences while ensuring safety through advanced monitoring and control features. Overall, the content offers an insightful overview of the technology driving the future of electric propulsion.

Takeaways

• 🚗 The shift toward vehicle electrification is opening new frontiers for high-performance propulsion in both motorsports and street vehicles.
• 🔋 Electric vehicle (EV) systems can be categorized into three main subsystems: high voltage, low voltage, and multiple CAN networks.
• ⚡ High voltage systems are powered by batteries typically exceeding 200 volts, which include components like contactors, inverters, and DC to DC converters.
• 🔌 An on-board charger converts grid AC power to high voltage DC power to charge the high voltage battery.
• 🏎️ Motors propel the vehicle and require an inverter to convert high voltage DC from the battery into regulated AC voltage.
• 🛠️ The AEM VCU (Vehicle Control Unit) plays a crucial role in managing power delivery and safety features during operation.
• 🔄 The low voltage circuit powers standard vehicle accessories and can be retained from internal combustion engine vehicles during conversion.
• 💡 Power Distribution Units (PDU8) simplify the control of low voltage systems by allowing centralized management through the VCU.
• 🌐 CAN bus networking facilitates communication between multiple devices, improving wiring efficiency and system integration.
• 🔒 Advanced safety features, including pre-checks and voltage regulation, enhance the reliability and enjoyment of EV conversions.

Q & A

What are the three main subsystems in electric vehicle (EV) electrical systems?

The three main subsystems are the high voltage circuit, low voltage circuit, and multiple CAN networks.

What is the role of the high voltage battery in an EV?

The high voltage battery, typically over 200 volts, supplies power to high voltage components like the motor, inverter combos, and the DC to DC converter.

How does an on-board charger function in an EV system?

An on-board charger converts grid AC power to high voltage DC power to charge the high voltage battery.

What is a DC to DC converter and how does it work?

A DC to DC converter acts like an alternator in internal combustion engine vehicles, converting high voltage power to maintain the charge of the low voltage battery.

How are motor inverters used in electric vehicles?

Motor inverters convert high voltage DC power from the battery to regulated AC voltage for motor propulsion, and each motor requires its own inverter.

What advantages do EV conversions have regarding low voltage systems?

EV conversions can retain the existing low voltage systems from internal combustion engine vehicles, making the transition easier.

What is the function of the PDU8 power distribution unit?

The PDU8 power distribution unit allows for the control of 12-volt switch devices through the VCU, simplifying wiring and programming.

What is CAN bus networking and why is it beneficial in EV systems?

CAN bus networking allows multiple devices to share data over a two-wire network, simplifying wiring and enhancing communication between components.

How does the VCU improve performance and safety in EV conversions?

The VCU integrates multiple systems, receiving data from various devices to ensure optimal performance and safety through pre-checks and real-time monitoring.

What safety features are incorporated into the EV conversion systems?

Safety features include redundant pre-checks before startup, voltage regulation based on battery temperatures, and checks on pedal sensor voltages to prevent failures.

Outlines

00:00

⚡ The Future of Vehicle Electrification

The video introduces the shift toward vehicle electrification, emphasizing its impact on high-performance propulsion in motorsports and street vehicles. It discusses the integration of electrical propulsion at the OEM level and the creation of new classes in motorsports. The video aims to provide an overview of the common electrical systems found in electric vehicle (EV) conversions and motorsport applications. It breaks down these systems into three main subsystems: high voltage circuits, low voltage circuits, and CAN networks. The high voltage system is powered by a battery, usually exceeding 200 volts, which includes key components such as contactors, a DC to DC converter, an onboard charger, and motors controlled by inverters. Battery packs, typically made up of lithium-ion cells, are available in various configurations. The importance of charging ports and DC to DC converters in maintaining the low voltage system is also highlighted, along with the use of smart shunts for battery management.

05:00

🔌 Efficient Control with CAN Bus Networking

This paragraph delves into the role of CAN bus networking in simplifying the wiring of electric vehicle systems. It highlights how multiple devices can share data over a two-wire network, facilitating communication and control across various components. The VCU 300 monitors two CAN networks while communicating with a laptop on a third. This enables the VCU to command inverters and control switched devices through PDU8 modules, which manage functions like vehicle wake state, cooling pump activation, and driving modes. The integration of these systems eliminates the need for independent control systems, reducing complexity. Safety features such as redundant pre-checks, voltage regulation based on battery temperature, and sensor voltage checks enhance the driving experience and reliability of EV conversions. This comprehensive approach ensures optimal performance and safety, making the electric vehicle as enjoyable on commutes as it is on the track.

Keywords

💡Electric Vehicle (EV)

An electric vehicle (EV) is a type of vehicle that is powered entirely or partially by electricity, utilizing electric motors for propulsion. In the context of the video, the move toward vehicle electrification represents a significant shift in the automotive industry, where traditional combustion engines are increasingly being replaced by electric systems. The video discusses how EV conversions can enhance performance and safety for motorsports enthusiasts, showcasing the evolution of vehicles in modern transportation.

💡High Voltage Circuit

The high voltage circuit refers to the electrical system in an EV that operates at voltages typically exceeding 200 volts, supplying power to essential components like the motor and inverter. This circuit is critical for the vehicle's propulsion, as it delivers the energy stored in the high voltage battery to the motors. The script emphasizes the importance of components such as contactors, inverters, and battery packs in this circuit, illustrating how they work together to facilitate efficient vehicle operation.

💡Low Voltage Circuit

The low voltage circuit in an EV operates at 12 volts, similar to traditional internal combustion engine vehicles. It powers various ancillary devices, including lights and accessories. The video highlights the role of a DC to DC converter in maintaining the low voltage battery charge by drawing energy from the high voltage system, thereby allowing EV conversions to retain familiar vehicle functionalities while benefiting from electric propulsion.

💡Battery Management System (BMS)

The Battery Management System (BMS) is a crucial component that monitors and manages the battery's performance, ensuring optimal charging and discharging cycles. It protects the battery from damage and prolongs its lifespan by preventing overcharging and overheating. In the video, the BMS works alongside other systems, such as smart shunts, to enhance battery safety and efficiency, illustrating its integral role in EV operation.

💡Inverter

An inverter is an electronic device that converts direct current (DC) from the battery into alternating current (AC) to drive the electric motor. The video explains that each motor requires its own inverter to function correctly, allowing for precise control over the vehicle's propulsion. This component is central to the performance of an EV, as it regulates power delivery and enables features like torque management and launch control.

💡CAN Bus

CAN Bus (Controller Area Network) is a robust vehicle bus standard that allows microcontrollers and devices to communicate with each other without a host computer. In the context of the video, the use of CAN Bus simplifies wiring and enhances communication between various electronic components, enabling them to share data efficiently. This integration is pivotal in achieving reliable performance and safety in EV conversions, as highlighted through the interaction between the vehicle control unit (VCU) and other systems.

💡Power Distribution Unit (PDU)

The Power Distribution Unit (PDU) is a device that manages and distributes electrical power to various systems within the vehicle. The video introduces the PDU8, which enables control of multiple 12-volt switched devices via a single connection to the VCU. This modular approach simplifies the wiring process and enhances the vehicle's overall efficiency, as it allows for strategic placement of power controls closer to their respective functions.

💡On-Board Charger

The on-board charger is a component that converts AC power from the electrical grid into DC power to charge the high voltage battery. The video explains its significance in the high voltage circuit, allowing EVs to be charged from standard outlets. This capability is crucial for the practicality and convenience of EV ownership, emphasizing the importance of charging infrastructure in supporting the growth of electric vehicles.

💡Torque Management

Torque management refers to the control of the torque produced by the electric motors to ensure smooth and efficient acceleration. In the video, the VCU utilizes torque management to enhance performance and maintain safety during vehicle operation. This feature is particularly important in high-performance applications, allowing drivers to tailor the driving experience and optimize power delivery based on conditions.

💡Safety Features

Safety features in electric vehicles are designed to prevent failures and ensure safe operation during driving. The video discusses various safety mechanisms, including redundant pre-checks of systems before startup and voltage regulation based on battery temperatures. These features are essential in EV conversions, as they help prevent potential hazards like overheating or component failure, ensuring a reliable and enjoyable driving experience.

Highlights

The shift towards vehicle electrification offers new opportunities for high-performance propulsion in motorsports and street vehicles.

EV electrical systems can be simplified into three main subsystems: high voltage circuit, low voltage circuit, and multiple CAN networks.

High voltage systems are powered by batteries typically over 200 volts, comprising numerous lithium-ion cells.

Key components of the high voltage system include the battery pack, on-board charger, contactors, and DC to DC converters.

The on-board charger converts grid AC power to high voltage DC power for efficient battery charging.

A DC to DC converter functions similarly to an alternator in internal combustion engine vehicles, maintaining the low voltage battery charge.

Smart shunts are integrated into battery management systems to monitor performance and ensure safety.

Inverters are crucial as they convert high voltage DC from the battery into regulated AC voltage for propulsion.

The Vehicle Control Unit (VCU) communicates with inverters via CAN bus to control power delivery and implement safety features.

Low voltage circuits in EVs can retain components from internal combustion engine vehicles, enhancing system compatibility.

Power Distribution Units (PDU8) streamline the control of 12-volt switched devices through the VCU, simplifying wiring.

CAN bus networking allows multiple devices to share data across a two-wire network, greatly simplifying electrical systems.

The AEM VCU integrates various systems to enhance vehicle performance and safety, moving beyond traditional isolated subsystems.

Safety features include redundant pre-checks of systems before startup to prevent overheating and component failures.

With proper setup, EV conversions can offer driving experiences comparable to original equipment (OE) vehicles.

Transcripts

the move toward vehicle electrification

presents enthusiasts with the new

frontier for high performance propulsion

for both motorsports and street

performance vehicles the future is

arriving now as we see the integration

of electrical propulsion being adopted

in mass at the oem level in motorsports

where new classes and entire race series

are being created and in the performance

enthusiast segment this video provides a

general overview the common electrical

systems found on an ev conversion or

motorsports application and the

components that are typically included

in the different systems

eevee electrical systems can seem

complex but if we peel away the layers

it becomes clear that it's not as

intricate as one may think

generally these systems can be broken

down into three subsystems a high

voltage circuit a low voltage circuit

and multiple can networks

high voltage or hv systems are supplied

by a high voltage battery typically over

200 volts and includes contactors which

relay power from the battery to the high

voltage components like the motor

inverter combos and a dc to dc converter

an on-board charger is used in the high

voltage circuit to convert grid ac power

to high voltage dc power to charge the

high voltage battery common components

of the high voltage system include the

battery pack on-board charging unit

contactors smart shunt motor or motors

an inverter or inverters if more than

one motor is being used for propulsion

the battery packs are generally

comprised of hundreds of individual

lithium ion cells and they're available

in a myriad of configurations

these packs typically range between 200

to 800 volts and common packs used in

conversions may include those from tesla

chevy nissan or other oe manufacturers

with battery electric or hybrid electric

vehicles while technically not a direct

part of the high voltage system the

charging port connects to the high

voltage system and allows you to charge

the vehicle from a 100 volt or 220 volt

outlet using a charging plug a dc to dc

converter acts like an alternator on an

internal combustion engine or ice

vehicle it's what allows the low voltage

battery to remain charged using energy

in the high voltage system

a smart shunt like the isabella hit ivts

series smart shunt has been used for

battery management but we incorporate

and recommend including it as an

integrated circuit voltage and

temperature sensor in conjunction with

the bms the motor or motors are what

propel the vehicle and they're

controlled by an inverter or inverters

each motor requires an inverter for

operation in this example you see a

cascadia motion ds-250-115

dual stack motor assembly which requires

an inverter for each motor an inverter

is a type of controller that takes high

voltage dc power in from the battery

packs and outputs a regulated ac voltage

to the motor or motors for vehicle

propulsion the aem vcu communicates with

the inverter via can bus to control

power delivery and implement both

performance and safety features and

that's where the magic starts to happen

things like torque management launch

control on the fly power levels and

robust safety checks by the vcu before

the high voltage system engages allow

you to truly tailor the driving

characteristics of your ev and prevent

damage in the event of component failure

by ensuring the system will not engage

until all pre-system checks across the

vehicle's circuits are completed and it

is verified that everything is working

correctly

most enthusiasts will be familiar with

the low voltage circuit since this

system is common to internal combustion

engine vehicles to power lights

accessories and the like

one of the many advantages of ev

conversions is the ability to retain an

internal combustion engine vehicle's

existing low voltage system as we

mentioned a dc to dc converter converts

power from the high voltage circuit to

charge the 12 volt battery which

supplies power to the low voltage

ancillary devices but these devices

still require a method of control and

unless you want to rewire your low

voltage accessories to individual

switches we've created a more elegant

solution in our pdu8 power distribution

units a great thing about can bus is

that allows you to control 12-volt

switch devices with our vcu using pdu8

power distribution modules placed

strategically throughout the vehicle so

instead of wiring to individual switch

functions with multiple relays for each

one you can wire your switched functions

to pdw8 connect your pdu8 to the vcu

using a simple two-wire can connection

and then program and control their

functions using aem cal software for the

vcus these small robust units can be

daisy-chained to control multiple switch

devices allowing you to place them

closer to the functions they're

controlling for easier wiring and since

the programming is done in the vcu

there's no need to carry dedicated

spares for each module at the rear of

the vehicle you can see a pdu8 that is

programmed to activate the inverters and

the cooling pump and control the

activation of the tail light splinkers

and reverse lights a second pd-w8 near

the front passenger seat footwell

controls the can keypad and digital dash

display while two additional pdu8s at

the nose activate the contactors for the

high voltage system and control the

headlights

can bus networking allows multiple

devices to share data across a two-wire

network which greatly simplifies wiring

our vcus are able to transmit and

receive data from multiple can networks

which allows them to supervise multiple

components to ensure optimum performance

and safety the vcu 300 is receiving data

from two can networks and communicating

with the laptop on a third network one

network communicates with and receives

data from the motor inverters cooling

pump and pd-8 power distribution units

from this network the vcu can command

the inverters and direct the control of

switched devices through the pdu8

modules which control everything from

the wake state of the vehicle and

activation of the cooling pumps to

regulate battery temperatures to

commanding drive mode through the vcu

programmed can keypad and controlling

the lights blinkers and other

accessories

the ability to connect multiple can

networks is another reason we call our

vcus the adult in the room with aem ev

no longer do enthusiasts have to rely on

a quote alphabet soup model of control

for their ev where the devices on each

subsystem operate independently and do

not communicate with one another our

vcus and can expansion devices like our

pdu8 can keypad digital dash displays

and battery management system integrate

all of these systems and the vcu

receives data from every device this

allows calibrators to achieve a level of

control performance and safety on par

with oe vehicles with proper setup the

days of welded contactors overheated

batteries and over current shutdowns are

over combined with safety features like

redundant pre-checks of the systems

before startup voltage regulation to the

motor based on battery temps safety

checks on pedal sensor voltages and more

all ensure that your ev conversion is as

enjoyable to drive on your commute as it

is at the next car cruise or track day

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