Design and implementation process for controls integration using CAN bus on a full function electric vehicle conversion

Abstract

From the electrical engineering perspective, this thesis addresses the design and implementation of the conversion process from a hybrid electric to a full function electric vehicle (FFEV). The architecture selection process and main components of an electric vehicle (EV) are described, and an exhaustive literature review on the controller area network (CAN) is presented. The electrical and control system integration strategy is explained, along with the model-based algorithm programmed into the vehicle integration module (VIM). Emulating electronic control units (ECUs) from the original powertrain and controlling additional ones for the electrical drivetrain through CAN bus, along with keeping the same functionalities of a typical production vehicle makes this vehicle conversion similar to a factory built model. Finally, the tests and results originating from this conversion to a full electric powertrain are discussed. The vehicle features a 83.5 kWh Li-ion battery built in-house, resulting in an estimated range of 482 km.