EV Conversion

Project Title

EV Conversion

Project Area of Specialization Mechatronics EngineeringProject Summary

National efforts to improve air quality in the country have revitalized the interest in development of electric vehicle technology that can be sustained for years to come. Battery powered vehicles not only offer a diminished carbon impact on our environment but also provide an economical alternative. Considering the high prices of commercially available electric vehicles, our project is aimed at converting an already available combustion engine model into a BEV (Battery Electric Vehicle). Our project addresses all design considerations involved in this conversion and comprises of the hardware implementation as well. The project kicks off from the removal of internal combustion engine and related assembly from a commercial vehicle (Suzuki Mehran). It then goes on to cover the design and development of EV controller, practicability of commonly used differentials, and development of EDS, if needed. After this, our efforts tend to direct towards installation of EV components and integration of accessory systems. All of this ends in implementing, testing and optimizing the designed system on the designated vehicle.

Project Objectives

• Design of EV controller
• Checking of feasibility of EDS integration withing EV- controller
• To analyze the difference between mechanical differential-oriented assembly and EDS differential assembly
• To implement and optimize our system on a physical setup 

Project Implementation Method

•Removal of combustion engine and other related components

•Procurement of electric components such as motor, motor driver and batteries

•Design and Construction Motor Controller and EDS

•Programming and testing of electric components accordingly

•Manufacturing of desired mounts for the components

•Installation of electric components

•Performing final configuration and testing

Benefits of the Project

Our FYP focusses on performing an EV conversion on a local car and making it feasible and affordable for the public, by designing and manufacturing our own motor controller in Pakistan. This will significantly lower the conversion cost, encouraging people to shift from environmentally harmful fossil fuels to electricity, as government of Pakistan aims to convert 30 percent of the country’s total transport to electric by 2030, which can save up to $2 billion in oil import bills.

Technical Details of Final Deliverable

For Performing the EV Conversion, we are using two 10kW BLDC motors and then designing and constructing the required BLDC motor controller for the motors, along with this we are planning to replace the mechanical differential of the car with an Electronic Differential System, which would also be designed and constructed by us. To run this system we require a 72V 180Ah li-ion battery which would let the vehicle travel a distance of around 80 miles on a single charge.

Final Deliverable of the Project HW/SW integrated systemCore Industry TransportationOther Industries Energy , Others Core Technology Clean TechOther Technologies OthersSustainable Development Goals Affordable and Clean Energy, Sustainable Cities and Communities, Climate ActionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	78872
Digital Potentiometer	Equipment	5	366	1832
Mosfet Clamps	Equipment	6	32	192
Crystal	Equipment	5	32	160
Board Mount DC-DC Converter	Equipment	5	1894	9472
Voltage Regulator	Equipment	5	146	728
3-Phase Gate Driver	Equipment	4	462	1848
Steering Wheel Angle Sensor	Equipment	1	14400	14400
Cable	Equipment	10	840	8400
Foot Throttle	Equipment	1	7840	7840
Power Mosfet	Equipment	8	3000	24000
Assembly Cost	Miscellaneous	1	10000	10000