Development of a refrofit kit for electric vehicle transformation

One of the biggest challenges of the automotive industry in recent history is the process of powering the vehicle by electricity which is called Vehicle Electrification. Electrification in the automotive industry is the process of converting a vehicle from a traditional fuel source to one powered by electricity. Generally, vehicle electrification focuses on the electric powertrain and related auxiliary systems, like on-board and off-board charging systems, as well as wireless power transmission. After İncreasing the importance of Vehicle Electrification, the proposal for the “EVERGRIN” project was introduced by Brain Technologies and Politecnico di Torino. EVERGRIN is an acronym that stands for – Device for Electric Vehicle ERGonomic for RINnovamento (renovation) and Revamping of Existing Vehicle with Traditional Engine. The vehicles undergoing the transformation are vehicles that have been produced and released since 2000, far from being "vintage". Production or replacement with new models for at least 5 years in the EURO 3 or EURO 4 emission class, characterized by a modest and not yet widespread presence of electronic components, but still fully functional and functional for a task, especially if it is an urban and suburban nature. Main activities of the EVERGRIN project are designing the architecture on Fiat Panda 2nd Series, development of new components (e.g. ABS), VMU development, HMI System development, Functional Architecture and Vehicle Network Integration, Test Bench Development and Development and Adaptation of Mechanical Parts. Therefore, the main goal of this thesis is to develop a VMU (Vehicle Management Unit) and functional architecture and vehicle network integration that can allow for more efficient vehicle conversion and management of the electric propulsion system. In that case we worked with the HY-TTC 32S ECU (Electronic Control Unit) which is equipped with a Watchdog and a Main CPU. The watchdog can be used to bring the Electronic Control Unit to a safe state by interrupting the Main CPU and disabling safety switches with using the dedicated output. It is based on an Infineon XC22xx microcontroller, and the software is written in C language. Control unit has 28 I/Os which are freely configurable and two can buses, one is using for the engine and safety systems and another one for the body controls (BCM, ABS, On-Board Systems, HVAC Heater, HMI). In conclusion, some high priority tasks of the VMU is implemented and the first task is focused on the pedal management (brake pedal and acceleration pedal) which has the most priority in the architecture of the car. Second task is behavior of the battery of the vehicle. Third one is related to inverter control and the last one is controlling the ABS of the car. Additionally, a debouncer task is implemented and it takes the input value and returns the debounced value in the output of the VMU. It is a general debouncer which can be used for the several purposes (diagnostic test etc.). The primary objective of the EVERGRIN project of Brain Technologies and Politecnico di Torino is vehicle electrification, or in our instance, the conversion of a diesel-powered FIAT PANDA into a completely electric vehicle. Thus, the objective is "Transformation (electrification) of a diesel-powered Fiat Panda car," i.e., converting it into a completely electric vehicle.