EV Glossary

Conversion cum Retrofitting

Electric vehicle conversion refers to the process of transforming a traditional, internal combustion engine (ICE) vehicle into an electric vehicle (EV). This conversion involves replacing the vehicle’s gasoline or diesel engine with an electric motor and installing a battery pack to store and provide electrical power. We can also develop hybrid vehicle that runs on both electric power and enginer power when required either combined or independently.

Here are the key steps involved in an electric vehicle conversion:

  • Remove the Internal Combustion Engine (ICE): The first step is to remove the existing gasoline or diesel engine, along with its associated components, such as the fuel tank, exhaust system, and radiator. This creates space in the vehicle’s engine bay for the electric components.
  • Install an Electric Motor: An electric motor, usually an AC or DC motor, is installed in place of the removed ICE. The motor’s power output should be selected based on the vehicle’s size and intended use.
  • Add a Battery Pack: A battery pack is installed in the vehicle, typically in the engine compartment, trunk, or under the chassis. The choice of battery type (e.g., lithium-ion, lead-acid) and capacity depends on the desired range and performance of the converted EV.
  • Integrate Motor Controller: A motor controller is essential to regulate the electric motor’s power output. It controls the speed and torque of the motor, ensuring smooth and efficient operation.
  • Charging System: An onboard charging system is integrated into the vehicle to allow it to be charged from external power sources, such as standard electrical outlets or dedicated EV charging stations.
  • Transmission and Drivetrain Modifications: Depending on the vehicle’s original transmission, modifications may be necessary to adapt it to the electric motor’s power delivery. In some conversions, the original transmission is removed, and a direct drive system is used.
  • Cooling and Heating Systems: Electric motors and batteries generate heat during operation, so a cooling system is often added to manage temperature. Additionally, a heating system may be installed to maintain cabin comfort.
  • Wiring and Electronics: The vehicle’s electrical system is rewired and adapted to accommodate the new electric components, including the motor controller, battery management system (BMS), and charging system.
  • Safety and Compliance: Conversions must adhere to safety standards and regulations, ensuring the vehicle meets safety requirements and can be registered and legally driven on the road.

Testing and Tuning: Once the conversion is complete, the converted EV is thoroughly tested to ensure all components work correctly. Fine-tuning may be necessary to optimize performance and efficiency.