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Electric Vehicle Conversion Guide Last Updated: 02/17/2023 |
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One of the emerging technology today is the Electric Vehicle (EV) Conversion as it promotes the recycling of vehicles, reduction of carbon footprint, lower repair and maintenance cost, and efficient performance. EV Conversion is defined as the modification of traditional internal combustion engine (ICE) cars to fully electric vehicles. A vehicle operating with an IC Engine is fully convertible to an electric vehicle by utilizing a battery pack as a replacement for the engine as well as the inclusion of an EV Conversion Kit such as a high-quality electric motor, premium-grade car battery, controller, contactors, and cables. For your next EV Conversion Project, factors such as upfront cost, range, charging time, speed, etc. should be considered. That is why knowing how to choose the right components will help in further increasing the efficiency of your electric vehicle to fit its desired application. This article aims to help in choosing the best component for your next conversion project by providing what you should know and what to avoid. KEY TERMINOLOGIES
In theory, the speed of the motor is directly proportional to the voltage. The output speed is faster when the input voltage is higher and vice versa. The torque can remain constant and the motor speed can be manipulated solely by increasing or decreasing the input voltage. Therefore, it dictates the top speed of the motor.
Amperage quantifies the amount of electrical charge flowing through a system, or the maximum amount of electrical current a system can safely handle. It is also proportional to the motor's torque where it reaches its peak current when the rotational speed is zero. It is regarded to signify the off-the-line performance of the motor.
The power in an electric motor is defined as the speed multiplied by the torque. Mechanical power is commonly measured in kW or horsepower (hp). Since voltage and torque are proportional to speed and current, respectively, it also reflects in their mechanical and electrical formula.
Energy storage systems, usually in the form of batteries, are required for all forms of electric cars. A rechargeable battery is used to power electric motors. Two of the most commonly used types of batteries used for EV Conversions are Lead-acid and Lithium-ion. Lead-acid batteries are much cheaper than lithium-ion batteries upfront, however, in terms of charging time and battery life, lithium-ion is much superior.
Electric motors generate motion by transferring electrical energy to mechanical energy. The interaction of a magnetic field and winding alternating (AC) or direct (DC) current generates force within the motor. MOTOR: POWER, CURRENT, AND VOLTAGE Voltage and current are the components of electrical power and it is what makes up a motor. It is computed using the following formula: Power= VoltageCurrent P=VI
Unit: Sample Calculation: Sample Motor Data:
144 V600 A=86,400 W=86.4 kW Therefore, utilizing a 144 Volt, 600 Amps motor produces a power of 86.4 kW.
BATTERY The battery required for an electric vehicle conversion is determined by the vehicle's required power, range, and space constraints. In order to choose a battery pack tailored to your needs, the following should be considered:
These two factors directly relate to each other. Compared to heavier cars, relatively lighter cars require minimal energy to turn. Therefore, it consumes less energy from the battery. The theoretical amount of energy consumed per mile of a vehicle can be calculated by dividing its weight by 10. It is important to note that this part of the calculation is to give an estimation of the energy consumption per mile. There are other factors to consider and it is only used to give a visual representation of the actual value. The formula is as shown below:
Sample Calculation: Sample Battery Data
The result of the previous calculation can now be related to the desired range. This is done by multiplying the two and the result is the energy consumption where it can be inferred that increasing the range will also increase energy consumption. energy consumption per mile x range=energy consumption Sample Calculation:
Knowing the energy that the vehicle will consume gives a clearer view of the battery pack that will be needed for the EV Conversion project. You may choose a battery that will suffice the demand of the vehicle. The energy consumption is the product of the voltage and the battery charge (ampere-hour). Therefore, you will be able to arrive at a suitable battery available in the market. battery voltage (V) battery charge (Ah)=capacity (Wh)Battery Types
Two of the most common types of batteries used for EV Conversion are Lead-Acid and Lithium-Ion batteries. One might ask whether your choice of battery type may affect your overall driving experience. The answer is yes, your battery may affect your overall driving experience. Lithium Ion battery costs more than Lead-Acid, however, the long-term benefits of using Lithium-Ion is far superior to the latter. A basic comparison chart for lead-acid and lithium-ion batteries is shown below:
The differences between these batteries also reflect in the calculation of the minimum range that the vehicle can travel utilizing the battery pack. To get the range, the capacity of the battery is divided by the energy consumption per mile. However, the total capacity of the battery is treated differently. In engineering, it is important to incorporate a factor of safety in each calculation. The factor of safety that will be used in the sample calculation is only 80% of the theoretical capacity. Additionally, the capacity of the Lead-Acid battery will initially be divided by two since it performs half as efficiently as Lithium-Ion.
Practical Application Based on the sample calculation, vehicles utilizing Lithium-Ion batteries have a better range than vehicles with Lead-Acid batteries. |
