Evolution of Electric Vehicles While in many fields of activity, technology becomes obsolete with such a speed that the world watches with amazement.

There is one technology, however, developed in early 1900's that we will carry with us into the 21st century - The Electric Vehicle. 1892 saw the development of the first electric vehicle (EV) which unfortunately was relegated to the background due to low cost of gasoline and the higher efficiency and speed of the internal combustion engine in conventional vehicles.

The plentiful availability of petroleum in the next few decades further stunted the growth of EV, until the mid 1970's. But EVs technology continued to be prohibitively expensive. As the price gap narrowed down and scarcity of petroleum-products began to surface, the time for the EV concept finally arrived some two decades later. Accelerated depletion of the World's oil reserves, growing concern over rising level of pollutants and emission, forced the attention of governments and communities on alternates.

The interest in Evs is thus re-awakening. These are zero emission vehicles that are also noiseless and therefore do not cause nose pollution either. EVs can be charged at home or at the office, saving queuing at filling stations. EVs are also easier to service and maintain and are ideal for 'stop-start' type of city driving conditions.

Further the absence of gears and clutch make them extremely reliable, safe and easy to drive and manoeuver in congested cities. Various studies conducted show that the potential for Evs is most attractive in countries like India, Brazil, and China - in that order. The advantages arise from a combination of factors such as urban congestion, high pollution levels and large car population in cities. India is endowed with low labour cost, low production start-up cost.

Added to this the potential for a huge domestic market, with lower investment than for an internal combustion engine, make EVs all the more attractive and advantageous. Companies in the developed countries are spending huge amounts money to develop electric cars that can travel longer distances in comfort. Unlike in the USA where these developments are taking place, very few people in India use their own vehicles for long distance travel, as the distance between two cities are too far and the poor conditions of roads.

The existing technologies available and suitability for in-city use, make EVs ideal for Indian cities. By taking advantage of this potential and an opportunity to be a leading global player for EV start up, the manufacturing sector can overtake the global automobile industry, given the latter's heavy investment in IC engine production and excess capacity. These and vested interest in IC are the inhibiting factors to EV development. In the words of N. Vittal, Chief Vigilance Commissioner of India, "This is an opportunity for India to lead the rest of the world in the global technology race."

Project REVA
The REVA Electric Vehicle project was conceived in 1994 as a long-term solution to the problems of air and noise pollution and based on the need for a compact, affordable, urban vehicle. Bangalore, where the project is located alone has over 200 new vehicle registrations per day. In a strategic alliance between Amerigon Electric Vehicle Technologies, (AEVT), USA and Maini Group, Bangalore, was born. AEVT, recognised as one of the world's leading EV designers and system integrators is a vehicle design, system integrators is a vehicle design, systems engineering and component supplier to the global automobile industry. Maini, a leading manufacturer of in-plant electrically operated material handling equipment is a diverse group engaged in manufacture of high-precision automotive components of OEM such as General Motors Limited.

Unlike conventional automobiles, EVs have to be produced in modest quantities, at a low price, with affordable tooling and manufacturing cost. Yet it must reflect the highest level of available technologies in design and function. Given these parameters, this joint venture is unique. This long term resource collaboration emcompasses all stages of the product - from concept to development and execution, besides technical, financial and commercial aspects. Maini which is providing highly skilled labour and cost effective manufacturing facilities, sent its engineers to America to develop the capability and skill required to work on the components and sub systems of Amerigon and other US companies. Several components sourced from India were also used for the prototypes tested at Amerigon.

After product development and testing, the designs and tooling were brought back to India, for production at Maini. Souring a high content level of locally sourced components is a pre-requisite for making the REVA really affordable and to this intent 99% of the 1100 parts that go into the REVA will be local, right from the launch of the vehicle. There has been a high level of encouragement and support to the project level of encouragement and support to the project, from both the US and Indian governments. USAID has extended substantial help and played a key role in the road tests of the REVA.

The name was christened by Frank Wisner, former US Ambassador to India. (it also happens to be the name of the Maini Group Chairman's wife). Planned for a mid 2000 release the REVA is expected to hit the roads soon, heralding in an era of non polluting, affordable, personal city transportation, which can be a boon to Indian cities.

The Silent Car Developed as an urban electric passenger car, the first REVA car was tested in mid 1996 after which it was tested extensively again at ARAI, Pune for homologation and was certified for road worthiness.

(The test included the 250,000 Kms Shaker Test). Further 10 REVAs have undergone extensive road testing in USA and in India.

The car was designed based on the feedback from 3000 people in 9 Indian cities. The requirement range from low purchase price, low operating cost, ease of driving and parking.

It took five years of intensive effort and an investment of US$ 20 million to get the REVA ready. Besides the manufacture, marketing too will be through REVA Electric Car Company (RECC) a JV between, initially will be a modest 1500 units per annum, which will be expanded to 12,000 vehicles per year, by 2004. Of this 15-20% is expected to be exported. The vehicle is a two door hatchback to carry two adults and two children or a payload of 227 kg. It can attain a top speed of 65 kmph, with a range of 80 kms.

Power derives from pack of eight 6 Volt EV type lead acid batteries. These can Amps) power supply. REVA also carries an on-board charger that is computer controlled and has a built in stabilizer and auto shut-off mechanism. The charge time is 7 hours, though 80% of the charge can be attained in 3 hours. High impact ABS is used to make the dent proof body panels. These are and also make recycling easier. The suspension consists of a MacPherson single a-arm in the front and coil spring in the rear, which facilitates good road handling and a smooth drive. The state-of the -art electronics functions as an efficient energy management system and advanced computerised vehicle diagnostics.

Side impact beams, a specially developed steel frame and electronic regenerative braking contribute to a high level of reliability and safety, according to the manufacturer. The high motor torque 70 NM enables quick acceleration and the absence of an engine gearbox or clutch, gives an excellent power to weigh ratio. The turning circle radius is only 3505 mm (3.5 metres) - the smallest for any car, manufactured in India. What's more, engine repairs, tuning, changing oils and filters, spark plugs and mufflers is now wonderfully a thing of the past. Some patent protected technologies imported for the development of EVs' include a running chassis, integrated power system (IPS), energy management systems (EMS) and climate control seats (CCS).

The chassis is a very strong self supporting space frame, made of light weight material. The motor, integrated power system, drive train, steering suspension, brakes, wheels, typres and high voltage systems are contained within this. ABS body panels are directly attached to the frame. Vehicles built using this technology require only a fraction of the capital costs, compared to conventional stamped sheet metal and assembly techniques. Even at the proposed low levels of production planned by RECC, this technology will help produce Rev at a very low cost. The integrated power system (IPS) used in REVA has achieved significant cost and weight reductions. The system is a proprietary technology developed by Amerigon and is patented. All major battery functions from charging and monitoring to range indication, motor control and power conversion for auxiliary systems and system diagnostic are managed by the IPS.

IPS also includes computer-based EMS, which optimises charging and energy output of batteries to maximise operating range and improve performance. Actually, the EMS has five key functions to collectively improve efficiency and reduce cost. Which are: charger control; state of charge (SOC) estimation; vehicle diagnostics; batter warranty verification and vehicle date acquisition (DAQ). The EMS also controls the outputs on the instrument panel of the REVA. This includes an SOC meter, efficiency gauge and diagnostics indicators. The EMS can also communicate with a hand held diagnostic unit or lap top computer for date acquisition and service diagnostics. These are usually found only in luxury cars like BMW, Mercedes, Audi etc. The next critical piece of equipment used in the REVA is the cooling, heating and ventilating system i.e. CCS. This equipment is protected by patents filed by Amerigon. This ventilates and cools/heats the seats to increase driver comfort under different weather conditions.

The CCS has a solid state heat pump and is extremely efficient (typically energy consumption is 10% less than that are used in conventional air-conditioner). As such, driving comfort is increased without compromising the travel range whether in hot or cold conditions. Testing ARAI - Automotive Research Association of India, Pune was the site of the four post, 2,50,000 kilometres shake testing, which determines the effect on structural integrity of the vehicle. The unique road conditions in India dogged by intense heat, humidity and monsoons combined with major fluctuations in power supply, necessitated testing in actual road conditions. Several REVAs were therefore subject to this test in Delhi and Bangalore, completing up to 50,000 kms. Since Evs have a limited range, non-accelerated endurance, testing is often time consuming. To overcome this an automated system with a tethered vehicle was specially developed. The vehicle is run on a 100 metres diameter circular track, with power supplied continuously via a cable.

The entire test operation is computer controlled and runs 24 hours a day, on a varying speed profile. The track contains bumps, potholes and a water trough with 45 cms of water in it. Indigenisation The basic principle in localizsing the parts and accessories has been to use locally available material to the maximum extent possible and use world's leading suppliers in areas where technology is not currently available, with the additional option of transferring the technology to India. On this project REVV has achieved the following: Designed and built in standard components that were already available in India, like lights, seals, steering systems, latches, locks etc. Worked with key Indian vendors, to develop parts that could be modified slightly to suit the requirements of REVA. Under this range comes the instrument cluster, brakes, suspension components and a few others.

Approached major Indian auto component suppliers to develop the proprietary components like transmission. Arranged difficult components like vehicle chassis, doors and critical castings and forgings through Maini Group Companies which have good experience in precision components and fabrication items. Signed MOUs with Maini Material Movement (MMM) and Maini Precision Products (MPP), to develop new techniques, i.e. body shop manufacturing facility with MPP and charger and EMS facilities with MMM. RECC worked jointly with some of the top suppliers of the world like Kostov, Bulgaria for the motor, Curtis PMC for the controller, Modular Power System, USA for the charger and CMP, UK for the batteries.

These vendors were roped into develop key components for the REVA and also invested several million dollars to develop and optimise these technologies.