FUEL EFFICIENCY IMPROVEMENT

BY USING ACETYLENE POWERED ENGINE

A project work submitted impartial fulfillment of the requirements for
The award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by

J. VISHNU VARDHAN 22X45A0305

K. AJAY 22X45A0307
K. SAI VENKATA NARAYANA 22X45A0308
P. UDAY BHASKAR 22X45A0318

Under the Esteem Guidance of

Mr. V. BALA CHINALINGAM ME

Assistant Professor

DEPERTMENT OF MECHANICAL ENGINEERING

S. R. K INSTITUTE OF TECHNOLOGY
Approved by AICTE,
Permanently Affiliated to JNTU Kakinada.
Accredited with NAAC ‘A’ grade.

ISO 9001: 2015 Certified Institution

ENIKEPADU, VIJAYAWADA – 5
2021 - 2024
1
 SRK INSTITUTE OF TECHNOLOGY
ENIKEPADU, VIJAYAWADA-521108

DEPARTMENT OFMECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the project entitled “FUEL EFFICIENCY IMPROVEMENT

BY USING ACETYLENE POWERED ENGINE”
Being submitted by

J. VISHNU VARDHAN 22X45A0305

K. AJAY 22X45A0307
K. SAI VENKATA NARAYANA 22X45A0308
P. UDAY BHASKAR 22X45A0318

In partial fulfilment for the award of degree of Bachelor of Technology (B. Tech) in
MECHANICAL ENGINEERING is a record of confide work carried out by them under my guidance
during the academic year 2024-2025 and it has been found worthy of acceptance according to the
requirements of the university.

Mr. P. TARUN NAGA VENKATESH [Link] Dr. P. KISHORE KUMAR, PhD.

Assistant Professor Professor & Head of the

Department
Project Guide Mechanical Engineering

Signature Of External Examiner

2
 DECLARATION

The Project is entitled “FABRICATION AND CONVERSATION OF IC

ENGINE TO PURE ELECTRIC VEHICLE” is record of Bonafide work carried out by
me and submitted in partial fulfillment for the award of Bachelor of Technology in
Mechanical Engineering to the Jawaharlal Nehru Technology University, Kakinada.

The results embodied in this thesis have not been submitted to any other university
or institute for the award of any degree.

Roll Number Name of the Student Signature of candidate

21X45A0332 P. DEEPAK NAGA SAI

20X41A0303 V. SIVA NAGESWAR RAO
20X45A0306 B. KARTHIK

3
 ACKNOWLEDGMENT

Behind every successful achievement lies great contribution by some great people. To
them although mere words of gratitude are insufficient for their unlimited contribution. I
take this opportunity to reveal my thanks to all of them who supported me in completing
this project work.

I wish to place on record my pro found graduated to my guide Mr. P. TARUN NAGA
VENKATESH, Assistant professor, SRKIT, Enikepadu, Vijayawada for his guidance,
encouragement, advice, mentoring and research support throughout my project. His ability
to teach, depth of knowledge and ability to achieve perfection will always be my
inspiration.

am indebted to Dr. P KISHORE KUMAR, Head of the Department of Mechanical,

for his moral support, inspiration and encouragement in the project completion.

I express my special thanks to Mr. EKAMBARAM NAIDU, Principal of SRK

Institute of Technology College, for providing the necessary infrastructure and
encouragement during the project period.

We would express our deep sense of gratitude to Management for providing us he

opportunity for doing a project and providing all the necessary resources and expertise for
this purpose.

Finally, I wood thank all the non-teaching staff of Mechanical engineering for their
consistent support in utilizing the labs. We would like to thank our parents, friends and
other well-wishers for their support.

P. DEEPAK NAGA SAI 21X45A0332

V. SIVA NAGESWAR RAO 20X41A0303
B. KARTHIK 20X41A0306

4
[Link] TABLE OF CONTENTS [Link]
TITLE PAGE 1
CERTIFICATE 2
DECLARATION 3
ACKNOWLEDGMENT 4
TABLE OF CONTENTS 5
LIST OF FIGURES & TABLES 6-7
ABSTRACT 8
CHAPTER-1
INTRODUCTION 9-18
1.1 INTRODUCTION OF ELECTRIC VEHICLES 9
1.2 TYPES OF ELECTRIC VEHICLES 9-14
1.3 ADVANTAGES OF ELECTRIC VEHICLES 15
1.4 DISADVANTAGES OF ELECTRIC VEHICLES 16-17
1.5 DISADVANTAGES OF IC ENGINES 18

CHAPTER-2
LITERATURE SURVEY 19-22

2.1 SURVEY OF ELECTRIC VEHICLES 19-20

2.2 STATE WISE ELECTRIC VEHICLES IN INDIA 21-22

CHAPTER-3

METHODOLOGY 23-31

3.1 IDEA OF ELECTRIC VEHICLES 23-25

3.2 COMPONENTS USED IN THE CONVERSION PROCESS 26-30

3.3 CALCULATIONS 31

5
 CHAPTER-4
FABRICATION AND CONVERSATION OF ELECTRIC 32-61
VEHICLES
4.1 FABRICATION PROCESS OF ELECTRIC VEHICLE 32-39

4.2 CUTTING PROCESS OF WHEEL SPROCKET – LASER CUTTING 39-41

MACHINING
4.3 CUTTING OF 2 WHEELER SPROCKET – WIRE CUTTING 41-43
MACHINING
4.4 BATTERY BED – ARC WELDING 43-45

4.5 CONVERSION PROCESS OF PETROL ENGINE TO ELECTRIC 45-61

VEHICLE

CHAPTER-5
FAILURES AND CHALLENGES FACED 62-68

5.1 FAILURES OF CONVERSION PROCESS 62-63

5.2 CHALLENGES OF CONVERSION PROCESS 63

5.3 CHALLENGES FACED BY A TEAM WHILE DOING A PROJECT 64-68

CHAPTER-6
RESULTS AND DISCUSSIONS 69-71

CHAPTER-7
CONCLUSION 72

CHAPTER-8
REFERENCES 73-75

6
7
[Link] TABLE OF PICTURES [Link]

1.1 BATTERY ELECTRIC VEHICLE 13

1.2 PLUG-IN HYBRID ELECTRIC VEHICLE 14
1.3 HYBRID ELECTRIC VEHICLE 16
1.4 FUEL CELL ELECTRIC VEHICLE 17
2.1 STATE-WISE ELECTRIC/BATTERY OPERATED VEHICLES 23
IN INDIA
3.1 BRUSH LESS DC MOTOR 29
3.2 SERIES CONNECTION 30
3.3 MOTOR CONTROLLER 30
3.4 REGENERATIVE BRAKING SYSTEM 34
4.1 MOTOR MOUNTING 36
4.2 BATTERY SET UP 37
4.3 COMPLETE DRIVE SYSTEM 37
4.4 FRONT SPROCKETS 37
4.5 BACK SPROCKETS 37
4.6 ELECTRIC VEHICLE CHARGER 38
4.7 EV CHARGING ADOPTER 39
4.8 CONTROLLER WIRING THROUGH THE BATTERY 40
4.9 CONTROLLER TESTING 41
4.10 CONTROLLER IS FIXED TO MOTOR 41
4.11 BODY UNDER WORKING 42
4.12 BODY AFTER COMPLECTION OF BATTERY BOX 43
4.13 FULL BODY MODIFICATION 43
4.14 LEASER CUTTING PROCESS 44
4.15 WIRE CUTTING PROCESS 46
4.16 COMPLETED W/P OF FRONT SPROCKET IN WIRE CUTTING 47
4.17 WELDING PROCESS 49

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4.18 BATTERY BED WELDING 50
4.19 BODY UNDER PAINTING 55
4.20 CHASSIS PAINTING 55
4.21 WIRING OF CONTROLLER TO MOTOR 56
4.22 COMPLETE WIRING OF THE VEHICLE 59
4.23 CONTROLLER CONNECTION 60
4.24 CONTROLLER SPECIFICATIONS WITH CONNECTIONS 61
4.25 FRONT SPROCKET FIXING 62
4.26 REAR SPROCKET 64
4.27 CHAIN FIXING TO THE SPROCKET AND WHEELE BED 64
5.1 GROOVE FAILURE 70
5.2 BATTERIES CONNECTED IN PARALLEL 71

TABLE:NO LIST OF TABLES P:NO

6.1 PERFORMANCE RANGE OF COMMERCIALLY AVAILABLE 71

EV
6.2 SPEED RANGES OF ELECTRIC BIKE ON DIFFERENT ROADS 71
6.3 EFFICIENCY OF THE BIKE WITH DIFFERENT LOADS 72

GRAPH:NO LIST OF GRAPHS P:NO

6.1 SPEED RANGE ON DIFFERENT ROAD CONDITIONS 72

6.2 EFFICIENCY OF DIFFERENT ROAD CONDITIONS 73

9
 ABSTRACT

This abstract tells the conversion of petrol vehicles into electric vehicles (EVs) as a
sustainable measure to tackle environmental concerns and reduce reliance on fossil fuels. It
addresses the technical, economic, and environmental aspects of this conversion process. The
technical considerations entail replacing or modifying key components like the internal
combustion engine and transmission to accommodate electric propulsion systems. Challenges
such as weight distribution and battery placement are evaluated to ensure optimal
performance and safety.

Economically, it analyze the feasibility of converting petrol vehicles to EVs, taking

into account initial conversion costs, potential savings from reduced fuel and maintenance
expenses, and available incentives for EV adoption. The main objectives of our work are to
reduce Carbon Emissions, Improve Air Quality, and Noise Reduction. To design and
optimize old petrol vehicle into new electric vehicle.

10
 CHAPTER 1
INTRODUCTION
1.1 ITRODUCTION ON ELECTRIC VEHICLES
Electric vehicles (EVs) are cars powered by electricity instead of gasoline, using rechargeable
batteries to store energy. They produce zero emissions, making them environmentally friendly
alternatives to traditional gasoline-powered vehicles. EVs are gaining popularity due to their
lower operating costs and reduced environmental impact. With advancements in battery
technology, EVs can now travel longer distances on a single charge, addressing range anxiety
concerns. Governments and industries worldwide are increasingly investing in EV infrastructure
to support the transition towards sustainable transportation.
Technological advancements are continuously improving the performance and capabilities of
electric vehicles. Manufacturers are developing more efficient batteries that can store more
energy and provide longer driving ranges on a single charge. Charging infrastructure is also
expanding rapidly, with more public charging stations being installed in cities and along
highways, making it easier for EV owners to recharge their vehicles conveniently. Furthermore,
research into renewable energy sources, such as solar and wind power, aims to make the
charging process even more sustainable and environmentally friendly.
With the current depletion of fossil fuels and its price hike, there is a need for another energy
resource to run the vehicle. The automobile sector is considering Electric Vehicle as a solution to
the industry and environment in India. Electric Vehicles are the replacement for petroleum-based
vehicles. They are one of the emerging technologies as well as eco-friendly and viable. The
replacement of internal combustion engines with electric engines will reduce pollution to a great
extent and be profitable to consumers. Many countries around the globe have implemented this
technology and are contributing towards betterment of the environment.
1.2 TYPES OF ELECTRIC VEHICLES:
1. Battery Electric Vehicle (BEVS)
2. Plug-In Hybrid Electric Vehicles (PHEVS)
3. Hybrid Electric Vehicle (HEVS)
4. Fuel Cell Electric Vehicle (FCEVS)
1. Battery Electric Vehicle (BEVs): Battery Electric Vehicles (BEVs) represent a

11
groundbreaking shift in automotive technology, propelled solely by electric power stored in
rechargeable batteries. Unlike conventional vehicles relying on fossil fuels, BEVs produce zero
tailpipe emissions, offering a sustainable and environmentally friendly transportation solution.
With advancements in battery technology, BEVs are becoming more accessible, providing
drivers with silent operation, instant torque, and the potential for reduced operating costs
compared to traditional vehicles.
Battery Electric Vehicles (BEVs) serve a variety of purposes across different sectors:
Personal Transportation: BEVs are used as everyday vehicles for commuting, running errands,
and recreational activities. They offer a clean and efficient mode of transportation for individuals
and families.
Commercial Fleets: Many businesses are incorporating BEVs into their fleets for deliveries,
transportation services, and other logistical needs. Companies are attracted to the lower operating
costs and environmental benefits of electric vehicles.
Public Transportation: BEVs are increasingly being adopted for public transportation systems,
including buses and taxis. Electric buses, for example, offer quieter operation and reduced
emissions, improving air quality in urban areas.
Government and Municipal Use: Governments and municipalities are integrating BEVs into their
vehicle fleets to reduce carbon emissions and showcase leadership in sustainability initiatives.
This includes electric police cars, utility vehicles, and more.
Ridesharing Services: Companies like Uber and Lyft are incorporating BEVs into their fleets to
offer eco-friendly transportation options to customers. Electric vehicles provide a more
sustainable alternative to traditional gasoline-powered ridesharing vehicles.
Last-Mile Delivery: BEVs are well-suited for last-mile delivery operations, especially in urban
areas where emissions regulations are strict. Electric delivery vans and trucks help reduce
pollution and noise in densely populated areas.
Home Energy Storage: Some BEVs can serve as energy storage units when they are parked and
plugged in. This vehicle-to-grid (V2G) technology allows BEVs to store excess energy from
renewable sources and discharge it back to the grid when needed, contributing to grid
stability and resilience

12
 FIG:1.1 BATTERY ELECTRIC VEHICLE (BEV)
2. Plug-In Hybrid Electric Vehicles (PHEVS): Plug-in Hybrid Electric Vehicles (PHEVs)
combine the benefits of both conventional internal combustion engines and battery electric
vehicles, offering a versatile and efficient mode of transportation. PHEVs can be plugged in to
charge their batteries, allowing them to operate solely on electric power for a limited range
before switching to a gasoline engine or other power source. This hybrid functionality provides
drivers with the flexibility of electric propulsion for shorter trips and the extended range of a
traditional vehicle for longer journeys.
Daily Commuting: PHEVs are ideal for daily commuting, offering the option to drive using
electric power alone for short distances, reducing fuel consumption and emissions during city
driving.
Long-Distance Travel: PHEVs provide the convenience of extended range for longer trips,
utilizing the gasoline engine for highway driving or when electric power is depleted, eliminating
range anxiety associated with pure electric vehicles.
Fleet Vehicles: Many businesses and government agencies incorporate PHEVs into their fleets
to reduce fuel costs, lower emissions, and showcase environmental responsibility.
Ridesharing Services: PHEVs are utilized by ridesharing companies to provide drivers with the
flexibility of electric power for city driving while still offering the range needed for longer trips.
Taxi Services: PHEVs are becoming popular choices for taxi services, offering fuel efficiency
and reduced emissions during stop-and-go city driving.
Personal Transportation: PHEVs are used by individuals and families as everyday vehicles,

13
offering the benefits of electric power for short trips and the extended range of a gasoline engine
for longer journeys.
Emergency Response Vehicles: Some emergency response agencies use PHEVs for vehicles
such as police cars and ambulances, taking advantage of the efficiency and low emissions of
electric power during city driving while maintaining the ability to travel long distances when
needed.

FIG:1.2 PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)

3. Hybrid Electric Vehicle (HEVS): HEVs, or Hybrid Electric Vehicles, are automobiles that
utilize both an internal combustion engine and an electric motor to propel the vehicle. They offer
improved fuel efficiency and reduced emissions compared to traditional vehicles solely powered
by internal combustion engines.
Hybrid electric vehicles offer several benefits and uses:

Fuel Efficiency: HEVs typically achieve better fuel economy than traditional gasoline vehicles

due to the combination of an internal combustion engine and an electric motor.

Reduced Emissions: By incorporating an electric motor, HEVs produce fewer emissions

14
compared to conventional vehicles, contributing to a cleaner environment.

15
Lower Operating Costs: With improved fuel efficiency, HEV owners can save money on fuel

expenses over time.

Regenerative Braking: HEVs utilize regenerative braking technology, which converts kinetic

energy into electricity to recharge the battery, improving overall efficiency and extending battery

life.

Increased Driving Range: Some HEVs offer extended driving ranges by combining the range

of both the internal combustion engine and the electric motor.

Enhanced Performance: Electric motors provide instant torque, resulting in smoother

acceleration and improved performance.

Environmental Benefits: HEVs help reduce reliance on fossil fuels and mitigate greenhouse gas

emissions, contributing to environmental sustainability.

Government Incentives: Many governments offer incentives, such as tax credits or rebates, for

purchasing HEVs to promote their adoption and reduce pollution

FIG:1.3 HYBRID ELECTRIC VEHICLE (HEV)

4. Fuel Cell Electric Vehicle (FCEVS): FCEVs, or Fuel Cell Electric Vehicles, are automobiles

16
that use hydrogen fuel cells to generate electricity, which powers an electric motor to propel the
vehicle. These vehicles emit only water vapor and heat as byproducts, making them zero-
emission vehicles. FCEVs offer the potential for long driving ranges and quick refueling times,
similar to conventional gasoline vehicles. They represent a promising technology in the pursuit of
sustainable transportation, offering an alternative to vehicles powered by fossil fuels.
Fuel cell electric vehicles (FCEVs) offer several uses and benefits:
Zero Emissions: FCEVs produce only water vapor and heat as byproducts, making them
environmentally friendly and contributing to cleaner air and reduced greenhouse gas emissions.
Long Range: FCEVs typically have longer driving ranges compared to battery electric vehicles
(BEVs), making them suitable for long-distance travel without the need for frequent recharging.
Quick Refueling: Unlike battery electric vehicles, which require lengthy recharging times,
FCEVs can be refueled quickly, similar to conventional gasoline vehicles, providing
convenience to drivers.
Versatility: FCEVs can be used across various transportation sectors, including passenger cars,
buses, trucks, and even trains, making them adaptable to different mobility needs.
Energy Security: Hydrogen, the fuel used in FCEVs, can be produced from a variety of domestic
sources, including renewable energy sources like solar and wind power, enhancing energy
security and reducing reliance on imported oil.
Quiet Operation: FCEVs operate quietly, contributing to reduced noise pollution in urban
environments compared to vehicles with internal combustion engines.
Potential for Grid Stabilization: FCEVs can serve as mobile power sources, with their fuel cells
capable of supplying electricity to buildings or the grid during emergencies or peak demand
periods, providing grid stabilization and backup power.
Government Incentives: Many governments offer incentives, such as tax credits or subsidies, to
promote the adoption of FCEVs and support the development of hydrogen infrastructure.

17
 FIG:1.4 FUEL CELL ELECTRIC VEHICLE (FCEV)

1.3 ADVANTAGES OF ELECTRIC VEHICLES

 Environmentally Friendly: Electric vehicles (EVs) produce zero tailpipe emissions,

reducing air pollution and greenhouse gas emissions, thus contributing to combating
climate change.
 Energy Efficiency: EVs are more energy-efficient than traditional internal
combustion engine vehicles, converting more of the energy from the grid into vehicle
movement.
 Reduced Noise Pollution: Electric motors are quieter than internal combustion
engines, leading to reduced noise pollution in urban environments.
 Lower Operating Costs: EVs generally have lower operating costs per mile
compared to conventional vehicles due to cheaper electricity compared to gasoline or
diesel.
 Lower Maintenance Costs: EVs have fewer moving parts than internal combustion
engine vehicles, resulting in lower maintenance requirements and costs.
 Government Incentives: Many governments offer incentives such as tax credits,
rebates, and subsidies to encourage the adoption of electric vehicles, making them

18
 more affordable for consumers.
 Range Improvement: Advances in battery technology have increased the range of
electric vehicles, alleviating range anxiety and making EVs more practical for
everyday use.
 Charging Infrastructure: The expansion of charging infrastructure, including
public charging stations and home charging solutions, has made it easier for EV
owners to charge their vehicles conveniently.

1.4 DISADVANTAGES OF ELECTRIC VEHCILE

 Limited driving range: Compared to traditional gasoline vehicles, electric vehicles

often have a limited driving range on a single charge, which can cause range anxiety
for drivers, especially on long trips.
 Long charging times: Charging an electric vehicle typically takes longer than
refueling a gasoline car, especially with standard home chargers, which can
inconvenience drivers.
 Lack of charging infrastructure: In many areas, there's still a lack of charging
stations, which makes it challenging for EV owners to find convenient places to
recharge their vehicles.
 Higher upfront costs: Electric vehicles generally have higher upfront costs than
their gasoline counterparts, mainly due to the expensive battery technology.
 Limited model options: The variety of electric vehicle models available on the
market is still relatively limited compared to traditional cars, which may limit
consumer choice.
 Battery degradation: Over time, the performance of electric vehicle batteries can
degrade, leading to reduced driving range and increased maintenance costs.
 Environmental impact of battery production: The production of electric vehicle
batteries requires rare earth metals and has environmental impacts, including carbon
emissions and resource depletion
 Weight of batteries: Electric vehicle batteries can be heavy, affecting the vehicle's

19
 overall weight distribution and handling characteristics.
 Cold weather performance: Electric vehicle batteries can lose efficiency in cold
weather, reducing driving range and requiring more frequent charging.
 Limited towing capacity: Electric vehicles often have lower towing capacities
compared to gasoline cars, limiting their utility for certain tasks.
 Difficulty in recycling batteries: Recycling electric vehicle batteries can be
complex and expensive, leading to concerns about proper disposal and environmental
impact.
 Dependency on electricity grid: Electric vehicles rely on the electricity grid for
charging, which can be susceptible to power outages and grid failure.

1.5 DISADVANTAGES OF IC ENGINE

 Environmental Pollution: ICE vehicles emit harmful pollutants such as carbon dioxide
(CO2), nitrogen oxides (NOx), particulate matter (PM), and volatile organic compounds
(VOCs), contributing to air pollution and climate change.
 Dependence on Fossil Fuels: ICE vehicles rely on finite fossil fuel resources such as
gasoline and diesel, leading to concerns about energy security, price volatility, and
geopolitical conflicts.
 Greenhouse Gas Emissions: The combustion of fossil fuels in ICE vehicles releases
CO2 and other greenhouse gases into the atmosphere, exacerbating global warming and
climate change.
 Noise Pollution: Internal combustion engines produce noise pollution, especially in
urban areas, which can negatively impact public health and quality of life.
 Lower Energy Efficiency: ICE vehicles have lower energy efficiency compared to
electric vehicles, as they waste a significant portion of the energy from fuel combustion
as heat and mechanical losses.
 Higher Operating Costs: ICE vehicles generally have higher operating costs due to the
relatively higher cost of gasoline or diesel fuel compared to electricity, as well as higher
maintenance and repair expenses.
 Complexity and Maintenance: Internal combustion engines have more moving parts
and require regular maintenance, including oil changes, filter replacements, and tune-
ups,
20
leading to higher maintenance costs and downtime.
 Limited Performance: ICE vehicles may have limited performance compared to electric
vehicles in terms of acceleration, torque delivery, and responsiveness, particularly at low
speeds.
 Emissions Regulations: ICE vehicles are subject to increasingly stringent emissions
regulations, requiring costly emission control systems and technologies to comply with
environmental standards.
 Health Risks: Exposure to air pollutants emitted by ICE vehicles, such as fine particles
and nitrogen oxides, can have adverse health effects, including respiratory problems,
cardiovascular diseases, and premature death.

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 CHAPTER 2
LITERATURE SURVEY
2.1 SURVEY ON ELECTRIC VEHICLES:
1. Omkar Tupe, Shweta Kishore and ArlophJohnvieria et all[1].

(2020) “ Consumer Perception on Electric Vehicles in India” European Journal of Molecular &

Clinical Medicine India's EV drive will open up a lot of business opportunities in the mobility,

infrastructure, and energy sectors if electric vehicle automobiles take off. And now consumers

are switching from fuel-powered automobiles to electric [Link] study helps in identifying

the consumer awareness and the factors that influence the consumer perception towards Electric

Vehicle. Some factors creates positive perception and motivates the consumer and few factors

discourages the consumers and act as the hindering factors ISSN 2515-8260 Volume 7, Issue 8,

2020.

2. . Indukala M. P., Bincy M. Mathew (2019) “A Study on future of Electric Vehicles in

India” International Journal of Advanced Research in Computer and Communication

Engineering. It is concluded that India has a lot to gain by shifting from ICE vehicles to EVs at

the earliest. The major gains include reduction in environmental pollution, reduction in oil

imports, improved national security, better economy and better utilization of renewable

[Link] 2278-1021 Vol. 8, Issue 6.

3. Yogesh Aggarwal, Vivek Gedda and Kushan Parikh (2019) “Indian Electric Vehicles Storm in

a teacup”. European Journal of Molecular & Clinical Medicine. It is concluded that With the

depletion of fossil fuels and constant hike in fuel prices, there is a need for energy transition in

vehicles in India. Govt has taken initiative to fight pollution levels by promoting EVs and giving

subsidies on purchase. To boost its production, Govt has eased the FDI norms. Various

emerging brands are launching EVs in India. The Government and manufacturers should join

22
their hands to build the infrastructure and create positive environment for EVs. ISSN 2515-8260

Volume 7, Issue 8, 2020

4. Janardan Prasad Kesari, Yash Sharma, Chahat Goel (2019) “Opportunities and Scope for

Electric Vehicles in India” International Journal of Mechanical Engineering. It is concluded that

analysis leads us to three main conclusions about the future of EV adoption in India. If both the

exchange and aggregation of demand work as expected, India could reach a volume of electric

vehicle sales of more than 1.6 million vehicles in fiscal year 23, mainly because of public

contracts and three-wheeled vehicles. Public procurement is expected to be an important driver

of growth in the coming years, with the purchase of four-wheeled vehicles for government

offices, three- wheeled vehicles and buses for public transport. If the government's 2030 targets

are met, India could save 8 INR lakh Cr (a 20% saving over a BAU scenario) on gasoline and

diesel imports for the industry during the period considered, after considering a certain level of

batteries. Thus, switching to electric vehicles will not necessarily reduce our import

dependency. However, the impact on the environment will be significant

Volume 6 Issue 5 Doi : 10.14445 / 23488360 / IJME-V6I5P101

5. A. Rakesh Kumar, Dr. Sanjeevi kumar Padmanaban (2019) “Electric Vehicles for India:

Overview and Challenges”. It is concluded that India has a huge challenge in shifting the

transportation sector from ICE engines to EVs. This requires a lot of planning, research and

development. Government policies like FAME and few other policies needs to be updated on

regular basis to keep in pace with the development throughout the world. India should focus on

improving the energy-efficiency of EVs. The power electronics, electric motors should planned

for Indian conditions. A battery eco-system needs to be develop which can support many

companies and start-ups developing battery pack up and cell manufacturing. Charging

23
infrastructure needs to be adequately build to address range anxiety. The options of swapping also be

explored. It is also very important to create demand generation by making all government buses

electric and offering tax exemptions for private EV owners. IEEE India Info. Vol. 14 No. 2.

2.2 STATE WISE ELECTRIC VEHICLES IN INDIA

 Uttar Pradesh has the highest registered e-vehicles i.e. 1.39 Lakh
 Delhi comes in second on the list with 75.7K registered e-vehicles
 It is speculated that these figures include mostly e-rickshaws and shuttles 27
 As the government aims for 3index has an altogether different story to tell.

FIG:2.1 STATE-WISE ELECTRIC/BATTERY OPERATED VEHICLES IN INDIA

 The minister also gave state-wise bifurcation of the registered electric vehicles. The

details showed that Uttar Pradesh has the highest registered e-vehicles i.e. 1.39 Lakh. It

was followed by Delhi and Karnataka at 75.7K and 31.94K respectively.

24
 The least number of electric vehicles were registered in Arunachal Pradesh with 13,

followed by Dadra and Nagar Haveli, Meghalaya and Mizoram at 14, 17 and 18

respectively. Last updated on 15 July 2019.

 The staggering difference between the adoption rates between these states raises bigger

questions on state-wise adoption of electric vehicles. The figure is contradicting to the

reports that India recorded sales of over 7.5 Lakh EVs in FY2019 as opposed to 56K in

FY18. This included the sale of 1.2 Lakh two-wheelers, 6.3 Lakh three-wheelers and

3,600 passenger vehicles.

 An ET report said that most of the vehicles in the government list are electric rickshaws

and e-carts, based on quotes from unnamed sources. These class of vehicles got legal

clearance in March 2015 and are recognized as motor vehicles officially.

 It is speculated that the actual number of electric vehicles would be much more than the

official figure. For one, thousands of electric rickshaws have been operating across

country without registration. Secondly, the data may not include figures from electric

two-wheeler and electric bicycle sales, and may also not have covered electric cars and

four-wheelers being operated by mobility startups and automotive companies.

 NITI Aayog had proposed that only electric vehicles should be sold in India by 2030. For

this, it called for full electric transition for three-wheelers by 2023 and two-wheelers with

an engine capacity less than 150 CC by 2025.

 The government on its part is taking initiatives such as exemption of registration fees of

electric vehicles and has also emphasised heavily on EVs in the Union Budget 2019.

Finance Minister Nirmala Sitharaman proposed a new scheme which will invite global

companies through a transparent competitive bidding process to set up mega

manufacturing

25
plants in sunrise and advanced technology areas including lithium storage batteries, and charging

infrastructure.

26
 CHAPTER 3
METHODOLOGY
3.1 IDEA OF ELECTRIC VEHICLE:
Firstly, our project members had decided to make a hybrid electric vehicle which is a fully

functional in condition. The working of electric vehicle as follows. Hybrid electric vehicles

(HEVs) combine the benefits of an internal combustion engine (ICE) with those of an electric

motor and battery system to improve overall efficiency and reduce emissions. During operation,

the vehicle’s powertrain control system monitors driving conditions and optimally selects

between the ICE, electric motor, or a combination of both to propel the vehicle. At lower speeds

and during light acceleration, the HEV primarily relies on the electric motor powered by the

battery pack, which is often recharged through regenerative braking. This electric propulsion

minimizes fuel consumption and emissions, particularly in urban driving scenarios. Conversely,

during higher speeds and heavy acceleration, the ICE may engage to provide additional power,

with the electric motor assisting when needed. This dynamic power management enables HEVs

to achieve better fuel economy and lower emissions compared to conventional vehicles, making

them a popular choice for environmentally conscious drivers seeking improved efficiency

without sacrificing performance.

27
Due to some financial issues and budget difficulties we decide to make an fully functional 2

wheeler electric vehicle from a 2 wheeler petrol engine vehicle .

Now the working of electric vehicle as follows. Electric two-wheelers, including electric

bicycles, scooters, and motorcycles, are gaining popularity as sustainable alternatives to

traditional gasoline- powered vehicles for urban commuting and short-distance travel. These

vehicles are powered by electric motors and rechargeable batteries, offering a quiet and

environmentally friendly mode of transportation. Electric two-wheelers are particularly well-

suited for congested city streets, where their compact size and agility allow for easy

maneuverability and efficient navigation through traffic.

With advancements in battery technology and electric drive trains, electric two-wheelers now

offer improved performance, range, and affordability, making them increasingly accessible to a

wide range of consumers. Many urban dwellers are turning to electric bicycles and scooters for

their daily commute, enjoying the convenience of zero emissions, low operating costs, and the

28
ability

29
to bypass traffic congestion. Additionally, electric two-wheelers contribute to reducing noise

pollution and reliance on fossil fuels, making them a sustainable transportation option for urban

environments facing environmental and congestion challenges. So it very easy to customize a

petrol vehicle into the electric vehicle than a hybrid electric vehicle

30
3.2 COMPONENTS USED IN THE CONVERSION PROCESS :
Converting a vehicle to electric power typically involves several key components:
1. Electric Motor: The heart of the conversion, replacing the internal combustion engine.
Power is converted from the DC battery to AC for the electric motor. The accelerator pedal sends
a signal to the controller which adjusts the vehicle's speed by changing the frequency of the AC
power from the inverter to the motor. The motor connects and turns the wheels through a cog.

FIG:3.1 BRUSH LESS DC MOTOR

2. Battery Pack: Provides the energy to power the electric motor. Lead-acid batteries can be
designed to be high power and are inexpensive, safe, recyclable, and reliable. However, low
specific energy, poor cold-temperature performance, and short calendar and lifecycle impede
their use. Advanced high-power lead-acid batteries are being developed, but these batteries are
only used in commercially available electric-drive vehicles for ancillary loads. They are also
used for stop-start functionality in internal combustion engine vehicles to eliminate idling during
stops and reduce fuel consumption.

31
 FIG:3.2 SERIES CONNECTION
3. Motor Controller: Regulates the power from the battery to the electric motor. Motor
controllers are devices which regulate the operation of an electric motor. In artificial lift
applications, motor controllers generally refer to those devices used in conjunction with
switchboards or VFDs to control the operation of the prime mover. Motor controllers often
include a manual or automatic means for starting and stopping the motor, selecting forward or
reverse rotation, speeding up or slowing down, and controlling other operational parameters. In
addition, motor controllers can provide protection for the artificial lift system by regulating or
limiting the torque, and protecting against overloads and faults. Many motor controllers contain
additional capabilities such as data collection and data logging as well as application-specific
control logic.

FIG:3.3 MOTOR CONTROLLER

4. Charger: Replenishes the battery pack's energy when plugged in. The design utilizes a
rectifier circuit for converting input AC voltage to high-voltage DC output, and it also
32
has an

33
electromagnetic interference (EMI) filter to eliminate high-frequency noise from the input
power source.
5. DC/DC Converter: Converts high voltage from the battery to the lower voltage needed for
accessories and charging the auxiliary battery. DC – DC Converter Transformers are used in
step- up or step-down converters. These transformers can be used in self-saturated or square
wave driven applications and have input voltage ranges of 5V, 12V, 24V, and 48V and output
Voltage up to 300 VDC. The power rating is up to 7.5 W for surface mount and up to 40W for
thru-hole transformers. The thru-hole version of the transformer is magnetically shielded. Pico
Electronics’ DC – DC Converter Transformers are operational over the temperature range from -
55C to +105C. All transformers are MIL – PRF – 27 Grade 5 Class S. These ultra-miniature
transformers are made for durability while maintaining their electrical characteristics. Custom
designs are available to increase or decrease secondary voltages as well as any specific input
voltages. Pico Electronics is an approved QPL source.
6. Thermal Management System: Keeps the battery pack and other components at optimal
operating temperatures. A Battery Thermal Management System (BTMS) is a system that
manages the heat dissipated or generated during the electrochemical process in cells of a battery
pack of an electric vehicle (EV). The objective of a BTMS is to avoid accelerated deterioration
of batteries and maintain battery operation at optimum temperature. It improves the battery
performance, lifetime, and safety of EVs.
When an EV battery is in operation, the electrochemical processes inside it produce heat which
increases the battery temperature. Hence it is required to maintain the EV battery's optimum
temperature to operate the battery safely and efficiently. The maximum battery performance is
obtained when the temperature is between 20-400C. If the temperature is less than 100C, the
charging capacity and efficiency of the battery are reduced. If the temperature rises beyond
800C, thermal runaway may occur resulting in the explosion of the battery.
7. Adapter Plate: Connects the electric motor to the transmission or drive train. Some adapter
plates may have more or less bolt holes than your make and model of vehicle requires. As some
adapters span a broad range of model years the adapter is designed to have enough bolt holes to
be compatible with all model designs.
8. Battery Management System (BMS): Monitors and manages the health of individual battery
cells within the pack. Battery management systems (BMSs) are used to monitor and protect a

34
rechargeable battery cell or battery pack and are often used in harsh and noisy environments – from
electric vehicles to industrial equipment. Safety and prevention of catastrophic failure is a
primary concern in the design of BMS. Therefore, it is important for timing solutions used in
BMSs to be robust and noise resistant.
Si Time MEMS timing products are built to operate reliably in extreme conditions, in high-current
environments and over wide temperature ranges. Our timing solutions are both resilient to
electromagnetic interference and have features to reduce system EMI.
9. Auxiliary Components: Including wiring, fuses, relays, and contactors to ensure safe and
efficient operation. As with gasoline-powered vehicles, electric vehicles have a number of
auxiliary systems. Some
Systems , such as the radio/tape player, lights, and horn, operate the same way as they do on a
gasoline- powered vehicle. Other systems, such as the power steering and power brakes, require
an additional small electric motor and have minor impact on the vehicle range. However, the
air conditioning and heating systems on electric vehicles are different and can have a dramatic
impact on the range.
Federal safety standards require all vehicles to have adequate heating and defrosting systems. The
heater/defroster system is easily operated in a conventional gasoline-powered vehicle because a
supply of heated water from the engine cooling system is readily available. Electric vehicles do
not have this heat source and therefore must provide the heat with an auxiliary heating system.
Some electric vehicles use an electric resistance heater, similar to a common hair dryer, which
requires electric power. This power must come from the main battery pack with a
corresponding decrease in vehicle range. Depending on the outside temperature and the desired
temperature in the vehicle, the range reduction can approach 35%.
10. Instrumentation: Provides information about battery state of charge, motor RPM, and other
vital data. This instrument panel for light electric vehicles (LEV) utilizes a highly integrated
system-on-chip (SoC) that consists of a power management unit (PMU), a graphical processor
(GPU), a Bluetooth® Low Energy (LE) radio, and an independent sensor block.
11. Regenerative Braking System: Captures energy during braking to recharge the battery pack.
Each component plays a crucial role in converting a vehicle from gasoline to electric power.
Regenerative braking is a unique technique that is used in EVs to capture energy that the vehicle
has due to its motion or, in other words, its kinetic energy that would have been wasted when the

35
vehicle decelerates or comes to a standstill while braking. By taking a measure of the initial and final
vehicle velocity, the amount of kinetic energy that is lost to braking can be calculated.
Urban drive cycles have a considerable amount of acceleration and decelerating periods due to
traffic control systems in place around towns and cities, and therefore, when decelerating,
significant energy is lost. However, with regenerative braking, this energy can be captured, and
‘waste’ energy can be harnessed and utilized for vehicle propulsion. Taking the Renault Zoe EV
as an example with one occupant with the vehicle mass as ~ 1600 kg with a speed of 120 km/h
(33.33 m/s), the kinetic energy has a value of 0.25 kWh. In a conventional ICEV, on approaching
a halt, this energy is totally wasted. Data obtained over a number of drive cycles in the Renault
Zoe show that this vehicle has an energy efficiency of ~ 0.2 kWh/km. An analysis of the energy
efficiency of the vehicle and kinetic energy the vehicle has lost due to braking shows that the
energy equivalent for the vehicle to travel 1.25 km is wasted when brought to a complete stop.
This range loss relates to a full cycle of the battery from 100% capacity to a completely
discharged battery.

FIG:3.4 REGENERATIVE BRAKING OF ELECTRIC VEHICLE

36
3.3 SPECIFICATIONS:
BRUSH LESS DC MOTOR SPECIFICATIONS:
RATED OPERATING VOLTAGE – 48V
RATED POWER – 1000W
NO LOAD CURRENT – 4.0A
NO LOAD SPEED – 500 RPM
RATED TORQUE – 102 KG-CM
RATED SPEED – 500RPM
RATED CURRENT – 13.4A
EFFICIENCY – 80%
GEAR RATIO – 6:1
CONTROLLER SPECIFICATIONS: RATED VOLTAGE – DC48V
RATED POWER - 1000W
RATED CURRENT – 30A
UNDER VOLTAGE PROTECTION – DC41.5V+-0.5A
CURRENT LIMITED - 30A+-0.5A
EFFICIENCY – 83%
CONSUMPTION - <1.5W
BATTERY - I POWER EXTRA
QUANTITY- 4*12V=48VOLTS
DRIVE SPROCKET – 13 TEETH
DRIVEN SPROCKET – 47 TEETH
NORMAL IC ENGINE USES – 114 LINKS, CHAIN DRIVE
R=N driven / N driver = 47/13 =3.615

37
 CHAPTER 4
FABRICATION AND CONVERSATION OF ELECTRIC
VEHICLE
4.1 FABRICATION PROCESS OF ELECTRIC VEHICLE
Converting a vehicle to electric power involves several fabrication processes. Some common
ones include:
Motor Mounting: Fabricating a mount to securely attach the electric motor to the vehicle's
chassis. Motor mounting in an electric vehicle conversion involves securely installing the
electric motor into the vehicle's chassis or frame. This process typically includes selecting
appropriate mounting points, fabricating or purchasing mounting brackets, and ensuring proper
alignment and clearance for the motor. Additionally, considerations such as weight distribution,
vibration dampening, and thermal management should be addressed during the motor mounting
process to ensure optimal performance and safety of the converted electric vehicle.

FIG:4.1 MOTOR MOUNTIG

Battery Integration: Designing and installing a system to house and connect the batteries,
including battery boxes or racks. The battery integration process typically involves designing,
testing, and incorporating batteries into a device or system. It includes aspects like selecting the
right battery type, determining placement, ensuring compatibility with the device's power

38
requirements, safety considerations, and optimizing for efficiency and longevity. Each step
involves careful planning and testing to ensure seamless integration and optimal performance.

FIG:4.2 BATTERY SETUP

Drive System Modification: Adapting or fabricating components such as drive shafts, axles, or
transmission systems to accommodate the electric motor's power delivery. Modifying a drive
system for an electric vehicle conversion involves replacing the internal combustion engine with
an electric motor, adding a battery pack, and integrating a motor controller. The specifics depend
on the vehicle's make and model, desired performance, and budget. It's crucial to ensure
compatibility, efficiency, and safety throughout the conversion process.

COMPLETE DRIVE SYSTEM FRONT SPROCKETS BACK SPROCKETS

FIG:4.3 FIG:4.4 FIG:4.5
Charging System Installation: Installing charging ports and associated electronics for charging
the vehicle's batteries. Converting a vehicle to electric involves installing a charging system to
power the battery. Typically, this includes mounting a charger unit, often onboard, and
connecting it to the vehicle's electrical system. The charger is then plugged into a power source,

39
like a charging

40
station or outlet, to replenish the battery. Depending on the setup, it may involve additional
components like a charge controller to manage the flow of electricity and ensure safe charging.

FIG:4.6 ELECTRIC VEHICLE CHARGER

41
 FIG:4.7 EV CHARGER WITH 48V 3A ADOPTER
Controller Installation: Mounting and integrating the motor controller, which regulates power
delivery from the batteries to the motor. The installation of a controller in an electric vehicle
conversion involves several steps:
Selecting the Controller: Choose a controller suitable for your vehicle's motor type, voltage,
and power requirements.
Mounting: Mount the controller securely in a location with adequate ventilation to dissipate heat.
Wiring: Connect the controller to the vehicle's battery pack, motor, throttle, and other necessary

42
components according to the manufacturer's instructions.
Programming: Some controllers may require programming to match the specifications of your
motor and vehicle. This typically involves adjusting parameters such as maximum current,
voltage limits, and throttle response.
Testing: After installation and programming, thoroughly test the system to ensure proper
operation and safety.
Integration: Integrate the controller with other vehicle systems such as regenerative braking,
display interfaces, and safety features.
Fine-tuning: Fine-tune the controller settings as needed to optimize performance.
Safety Considerations: Ensure all connections are secure and properly insulated to prevent
electrical hazards. Test emergency shutdown procedures and safety features.
Remember to consult with experienced individuals or professionals if you're unfamiliar with
electric vehicle conversions to ensure a safe and successful installation.

FIG:4.8 CONTROLLER WIRING THROUGH THE BATTERY

43
 FIG:4.9 CONTROLLER TESTING

FIG:4.10 CONTROLLER IS FIXED TO MOTOR

44
Body Modifications: Depending on the vehicle's original design, some body modifications may
be necessary to accommodate the new components or optimize aerodynamics for
electric propulsion. Body modification in electric vehicle conversion can involve several aspects,
such as altering the chassis to accommodate battery placement, reinforcing the frame to support
the added weight of batteries, and modifying the vehicle's body to enhance aerodynamics for
better efficiency. Additionally, some enthusiasts may opt for cosmetic changes like custom paint
jobs or body kits to give their converted electric vehicle a unique look.

FIG:4.11 BODY UNDER WORKING

FIG:4.12 BODY AFTER COMPLETION OF BATTERY BOX

45
 FIG:4.13 FULL BODY MODIFICATION

4.2 CUTTING PROCESS OF WHEEL SPROCKET – LASER CUTTING

MACHINING
Laser cutting is a highly precise and efficient manufacturing method used for cutting complex
shapes and designs from various materials, including metals like steel and aluminum commonly
used in the fabrication of 2-wheeler wheel sprockets. The process involves the use of a focused
laser beam to heat and vaporize or melt away the material along the desired cutting path,
resulting in clean and precise cuts.

46
 FIG:4.14 LEASER CUTTING PROCESS

For cutting a 2-wheeler wheel sprocket, the process typically begins with the creation of a digital
design file representing the sprocket's shape and dimensions. This design file is then imported
into specialized CAD/CAM software, where engineers or designers can specify cutting
parameters such as cutting speed, laser power, and focus depth. Once the cutting parameters are
set, the material sheet containing the sprocket design is placed onto the laser cutting machine's
cutting bed. The laser cutting machine then precisely directs the laser beam according to the
design file, tracing the outline of the sprocket onto the material surface. As the laser beam
interacts with the material, it heats and vaporizes or melts away the material along the cutting
path, leaving behind a clean and precise cut. Some of the drawbacks had been achieved during
the process of laser cutting process as follows:
Material Thickness Limitations: Laser cutting machines may have limitations regarding the
thickness of the material they can effectively cut. If the sprocket material is too thick, it may
require multiple passes or alternative cutting methods, which can increase production time and
costs.

47
Edge Quality: While laser cutting produces clean and precise cuts, the edges of the cut may exhibit

48
some degree of roughness or burring, particularly in thicker materials or when cutting at high
speeds. Additional finishing processes such as deburring or grinding may be required to achieve
the desired surface finish for the sprocket teeth.
Cost of Equipment and Maintenance: Laser cutting machines can be expensive to purchase
and maintain, especially high-powered machines capable of cutting thick materials efficiently.
Additionally, regular maintenance and calibration are necessary to ensure optimal performance
and accuracy, adding to the overall operating costs.
So due to main drawback of the centering of the hole of wheel sprocket required wheel sprocket
is not achieved.
4.3 CUTTING OF 2 WHEELER SPROCKET – WIRE CUTTING
MACHINING
Cutting a two-wheeler sprocket using a wire cutting process can be quite challenging due to the
material and precision required. Wire cutting, also known as wire EDM (Electrical Discharge
Machining), involves using a thin wire electrode to cut through electrically conductive materials
with high precision. In metal cutting processes, wire cutting, also known as wire EDM
(Electrical Discharge Machining), uses a thin, electrically conductive wire to cut through metal
by generating electrical sparks. The wire, typically made of brass or copper, is guided along a
programmed path to erode the workpiece material with precise control, producing intricate
shapes and profiles. It's commonly used for cutting intricate shapes in hardened metals and alloys
where traditional machining methods are impractical. The wire cutting process, or wire EDM, is
widely used in various industries for its ability to cut intricate shapes in hard materials with high
precision. Some common uses include:
Tool and die making: Wire cutting is used to create complex shapes and profiles in hardened
tool steel, carbide, and other materials used in tool and die manufacturing.
Aerospace industry: Wire EDM is employed to manufacture precision components for aircraft
engines, structural parts, and other aerospace applications where tight tolerances and intricate
geometries are required.
Automotive industry: Wire cutting is used in automotive manufacturing for producing molds,
dies, and components with precise shapes and dimensions, such as gears, pistons, and injection
molds.
Medical device manufacturing: Wire EDM is utilized to fabricate intricate and small-scale

49
components for medical devices, implants, and surgical instruments with high accuracy and
minimal material distortion.

FIG:4.15 WIRE CUTTING PROCESS

Preparation: Ensure that the two-wheeler sprocket is securely mounted and positioned properly
for the wire cutting process.
Machine Setup: Set up the wire EDM machine according to the specifications required for
cutting the material of the sprocket. This includes adjusting parameters such as wire tension,
flushing rate, and power settings.
Programming: Program the wire EDM machine with the specific dimensions and cutting path
required for the sprocket. This may involve using CAD/CAM software to create a precise cutting
path.
Cutting: Initiate the wire cutting process. The machine will use a high-voltage electrical
discharge to erode the material along the programmed cutting path. The wire electrode will
slowly cut through the sprocket material with extreme precision.
Monitoring: Throughout the cutting process, monitor the machine to ensure that the cutting is

50
proceeding smoothly and accurately. Adjust parameters as necessary to maintain quality and
precision.
Finishing: Once the cutting is complete, remove the sprocket from the machine and inspect it for
any imperfections. Depending on the requirements, additional finishing processes such as
deburring or surface treatment may be necessary.
Quality Control: Perform quality control checks to ensure that the cut sprocket meets the
required specifications and tolerances.

FIG:4.16 COMPLETED WORK PIECE OF FRONT SPROCKET IN WIRE CUTTING

METHOD
4.4 BATTERY BED – ARC WELDING:
Welding the battery bed from a two-wheeler EV petrol tank involves several steps to ensure a
strong and secure bond between the components. Here's a general process for welding the battery
bed:
1. Preparation:
Clean the surfaces of the petrol tank that will be welded together to remove any dirt, grease, or
contaminants.
Ensure that the surfaces are free from rust, paint, or any other coatings that could interfere with
the welding process.
Roughen the surfaces to be welded using a wire brush or sandpaper to improve adhesion.
2. Alignment:
Align the components of the battery bed within the petrol tank to ensure proper fit and
positioning. Use clamps or fixtures to hold the components in place during welding to prevent
51
movement or

52
misalignment.
Selection of Welding Method:
Choose an appropriate welding method based on the materials involved and the desired strength
of the weld.
Common welding methods for joining metal components include MIG (Metal Inert Gas)
welding, TIG (Tungsten Inert Gas) welding, or spot welding.
3. Setup:
Set up the welding equipment according to the chosen welding method, including selecting the
appropriate welding machine, electrodes, or filler materials.
Adjust the welding parameters such as voltage, current, and wire feed speed for MIG welding, or
amperage and shielding gas flow for TIG welding.
4. Welding:
Start the welding process by striking an arc or initiating the welding operation according to the
selected method.
Apply the welding heat gradually and evenly to the joint area, moving the welding torch or
electrode in a controlled manner along the weld seam.
Ensure proper penetration and fusion between the components to create a strong bond.
Pay attention to the welding technique, maintaining a consistent travel speed and distance from
the joint to achieve uniform weld bead formation.
Make multiple passes if necessary to achieve the desired weld strength and thickness. Welding is
a fabrication process that joins materials, usually metals or thermoplastics, by causing
coalescence. This is often done by melting the workpieces and adding a filler material to form a
weld pool that cools to form a joint. Here are some common welding processes:
Arc Welding This includes processes like Shielded Metal Arc Welding (SMAW), Gas Metal Arc
Welding (GMAW), and Gas Tungsten Arc Welding (GTAW). They use an electric arc to create
heat and melt the metal. Gas Welding This involves using a gas flame to generate heat for
melting the materials and sometimes a filler rod is added.
Resistance Welding This includes processes like Spot Welding and Seam Welding, where the
heat is generated by the resistance of the materials to electric current flow.

53
 FIG:4.17 WELDING PROCESS

FIG:4.18 BATTERY BED WELDING

4.5 CONVERSATION PROCESS OF IC ENGINE TO ELECTRIC
VEHICLE:
1. Selection Of Vehicle
2. Disassembling Of Petrol Vehicle
3. Cleaning Of Vehicle Chassis
4. Painting Of Vehicle Components

54
 5. Assembling Of Vehicle Components
6. Assembling Of Electric Vehicle Components
7. Wiring Of Electric Components
8. Controller Connections
9. Testig Of Electrical Components
10. Fixing Of Finished Sprocket To Vehicle
11. Testing Of Vehicle
12. Finishing The Process & Vehicle Getting Ready
13. Finally The Vehicle Conversion Is Completed
1. SELECTION OF VEHICLE: Ultimately, the best vehicle for an EV conversion depends on
your specific needs, preferences, and constraints. Take your time to research and consider all
factors before making decision.
Selecting a vehicle for an EV conversion involves several considerations to ensure a successful and
satisfying outcome:
Weight: Opt for a vehicle with a weight that's suitable for the intended use and battery capacity. Lighter
vehicles generally require less energy to operate and can provide better range.
Space: Look for a vehicle with enough space to accommodate batteries, motor, and other conversion
components without compromising passenger or cargo space too much.
Chassis Strength: Ensure the chassis is strong enough to support the added weight of batteries and other
components. Reinforcements may be necessary in some cases.
Availability of Conversion Kits: Some vehicles have readily available conversion kits, which can simplify
the conversion process and ensure compatibility of components.
Drive Train: Consider the vehicle's original drive train layout (front-wheel, rear-wheel, or all-wheel drive)
and how it aligns with your conversion plans. Rear-wheel drive vehicles are often easier to convert.
Budget: Factor in the cost of the vehicle itself, as well as the cost of conversion components and labor.
Sometimes starting with a cheaper, used vehicle can save money for the conversion process.
Skill Level: Assess your own mechanical skills and the complexity of the conversion. Some vehicles may be
easier to work on for beginners, while others require more expertise.
Regulations and Emissions: Check local regulations regarding EV conversions and emissions requirements.
Some areas may have restrictions or specific requirements for converted vehicles.
Desired Range and Performance: Consider the desired range and performance of the converted vehicle.
This will influence the size and type of batteries, as well as the motor and controller [Link]
Appeal: Choose a vehicle that you personally like and feel proud to drive. After all, part of the joy of an

55
EV conversion is the satisfaction of driving a unique, customized vehicle.2. Disassembling Of Petrol
Vehicle
2. DISASSEMBLING OF PETROL VEHICLE: Disassembling a petrol vehicle can be
complex and should be done carefully to avoid damage or injury. It typically involves tasks like
removing components such as the engine, transmission, exhaust system, and various other parts.
Each component needs to be handled with care and often requires specific tools and expertise. If
you're considering disassembling a petrol vehicle, it's important to have a clear plan, appropriate
workspace, and preferably some mechanical knowledge or assistance.
Disassembling a petrol vehicle can be done using various methods depending on the level of
disassembly required and the specific components you need to access. Here are some common
methods:
Engine Removal: Disconnecting and removing the engine is often a major part of disassembly.
This involves disconnecting all wiring, hoses, and mounts, then lifting the engine out of the
vehicle.
Transmission Removal: If necessary, the transmission can be separated from the engine and
removed independently. This typically involves disconnecting linkages, wiring, and support
brackets.
Exhaust System Removal: The exhaust system, including the manifold, catalytic converter, and
muffler, may need to be disconnected and removed to access other components.
Suspension and Drivetrain Disassembly: Depending on the repair or modification being
performed, components like suspension parts, axles, driveshafts, and differential may need to be
disassembled and removed.
Interior Removal: For certain repairs or modifications, it may be necessary to remove interior
components such as seats, carpeting, trim panels, and dashboard components.
Electrical System Disconnection: Before disassembly, it's important to disconnect the vehicle's
electrical system to prevent damage to electrical components and ensure safety.
Use of Specialized Tools: Some components may require specialized tools for removal, such as
pulley pullers, ball joint separators, or torque wrenches.
Reference to Service Manual: Consulting the vehicle's service manual is crucial for
understanding the specific disassembly procedures and ensuring that steps are followed correctly.
Organized Disassembly: Keep track of all removed components and hardware, labeling or

56
organizing them to ensure proper reassembly later.
Safety Precautions: Always take necessary safety precautions, such as wearing protective gear
and using proper lifting techniques when working with heavy components.
Assistance: In some cases, disassembling a petrol vehicle may require assistance from someone
with mechanical expertise or experience, especially for tasks involving complex systems
or tight spaces.
3. CLEANING OF VEHICLE CHASSIS: Cleaning the chassis of a vehicle is essential for
maintenance and longevity. Start by removing any loose debris, then use a degreaser to break
down any grease or grime. Scrub the chassis with a brush and rinse thoroughly. Make sure to dry
it completely to prevent rust.
There are several methods to clean a vehicle chassis effectively:
Pressure Washing: Use a pressure washer with a degreaser to blast away dirt, grease, and
grime. Be careful with the pressure setting to avoid damaging sensitive components.
Hand Scrubbing: Use a stiff brush and a suitable cleaner or degreaser to scrub the chassis
manually. This method allows you to target specific areas and ensure thorough cleaning.
Steam Cleaning: Steam cleaning is effective for removing tough grime and grease without the
need for harsh chemicals. It's environmentally friendly and can penetrate hard-to-reach areas.
Chemical Cleaners: There are various chassis cleaners and degreasers available in the market.
Apply the cleaner according to the manufacturer's instructions, let it sit for a few minutes to
break down dirt and grease, then rinse it off thoroughly.
Undercarriage Sprays: Undercarriage sprays are specifically designed to reach the underside of
the vehicle and remove road salt, mud, and other debris. These sprays often come with extension
wands to reach inaccessible areas.
Rust Prevention: After cleaning, consider applying a rust inhibitor or undercoating to protect
the chassis from corrosion.
4. Painting Of Vehicle Components: Painting vehicle components can be a great way to
customize or restore them. Just make sure to properly prep the surface, choose the right type of
paint for the material, and apply thin, even coats for the best results.
Painting vehicle components involves several key steps to ensure a professional finish and long-
lasting protection. Here's a general guide in a controlled environment, depending on the type of
paint used.

57
Preparation: Proper preparation is essential for a successful paint job. This includes cleaning
the components thoroughly to remove any dirt, grease, or contaminants. Sanding may also be
necessary to create a smooth surface for the paint to adhere to.

Masking: Use masking tape and paper to cover any areas that you don't want to be painted, such
as connectors, bolts, or sensitive electronic components. This helps to ensure clean lines and
prevents overspray

Priming: Applying a primer is crucial for promoting adhesion and providing a uniform surface
for the paint to adhere to. Choose a primer specifically formulated for use on automotive
components and follow the manufacturer's instructions for application.

Painting: Select a high-quality automotive paint that is suitable for the type of component you're
painting (e.g., plastic, metal). Spray the paint evenly over the surface, using smooth, overlapping strokes
to achieve full coverage. It's important to apply multiple thin coats rather than one thick coat to prevent
runs and drips. Drying/Curing: Allow the paint to dry/cure according to the manufacturer's instructions.
This may involve air drying or baking the components
Finishing Touches: Once the paint has fully cured, you may choose to apply a clear coat for added
protection and a glossy finish. Again, follow the manufacturer's instructions for application and
drying/curing times.
Final Inspection: After the paint has fully cured, carefully remove any masking tape and
inspect the components for any imperfections. Touch up any areas as needed, and ensure that the
finished result meets your expectations.
By following these steps and using quality materials, you can achieve professional-looking
results when painting vehicle components. Additionally, always work in a well-ventilated area
and wear appropriate safety gear, such as a respirator mask and gloves, to protect yourself from
Harmful fumes and chemicals.

58
 FIG;4.19 BODY UNDER PAINTING

FIG:4.20 CHASSIS UNDER PAINTING

59
 FIG:4.21 CHASSIS AFTER COMPLETION OF PAINTING
5. ASSEMBLING OF VEHICLE COMPONENTS: Assembling vehicle components
involves fitting together various parts such as the engine, transmission, chassis, and body panels
to construct a complete vehicle. This process requires precision, attention to detail, and
adherence to safety standards to ensure the final product meets quality and performance
requirements.
Assembling vehicle components typically involves several steps:
Preparation: Organize all necessary parts and tools.
Chassis Assembly: Begin with the frame or chassis, attaching major components like the engine,
transmission, and suspension.
Body Assembly: Attach body panels, doors, windows, and interior components.
Electrical Wiring: Install the wiring harness and connect electrical components such as lights,
sensors, and entertainment systems.
Final Assembly: Fit remaining components like tires, wheels, seats, and trim.
Quality Control: Inspect the vehicle for any defects or issues, ensuring it meets safety and quality
standards.
Testing: Conduct tests such as road tests, emissions tests, and quality checks to ensure the vehicle
functions correctly.
6. ASSEMBLING OF ELECTRIC VEHICLE COMPONENTS: Assembling an electric

60
motor typically involves several steps, such as winding coils, assembling the rotor and stator,
installing

61
bearings, connecting wires, and finally enclosing the motor in its housing. The exact process can
vary depending on the type and size of the motor being assembled. Is there a specific aspect
you'd like to know more about?
Assembling an electric motor typically involves several steps:
Preparation of Components: Gather all necessary components including the stator, rotor, bearings,
shaft, housing, and any additional parts.
Stator Assembly: Place the stator core into the stator housing, ensuring it is properly aligned.
Windings are then inserted into the slots of the stator core, and connections are made as per the
motor design.
Rotor Assembly: Assemble the rotor by attaching the rotor core to the shaft. Balance the rotor if
required, and install any necessary components such as fans or cooling fins.
Bearing Installation: Mount bearings onto the shaft, ensuring proper alignment and lubrication.
Housing Assembly: Place the stator assembly and rotor assembly into the motor housing, ensuring
correct alignment and clearances.
Terminal Box: Attach the terminal box or housing to the motor, connecting the windings to the
appropriate terminals.
Final Checks: Verify that all components are securely fastened and aligned. Check for any loose
connections, and ensure proper insulation and grounding.
Testing: Conduct initial tests to ensure the motor operates correctly. This may involve running the
motor at various speeds and loads to check for any abnormalities.
Finishing Touches: Apply any necessary protective coatings or covers, and label the motor with
relevant information such as model number, specifications, and ratings.
Packaging and Shipping: Once the motor passes all tests and inspections, it can be packaged for
shipping or installed in its intended application.

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 FIG:4.21 ASSEMBLING OF MOTOR
7. WIRING OF ELECTRIC COMPONENTS: Wiring electric components involves
connecting them in a circuit to allow the flow of electricity. This typically includes using wires,
connectors, and terminals to create a complete path for the electrical current. Are you working on
a specific project or need help with a particular aspect of wiring?
The purpose of wiring electric components is to create a pathway for the flow of electrical
current, enabling the components to work together as part of a larger system or circuit. Proper
wiring ensures that electricity is distributed efficiently and safely to power the intended devices or
perform desired functions. Additionally, wiring facilitates organization, maintenance, and
troubleshooting of electrical systems.
The process of electric wiring typically involves several steps:
Planning: Determine the layout of the electrical components, including the placement of outlets,
switches, and fixtures. Consider the electrical requirements of each component and the overall
circuit design.

63
Gathering materials: Collect the necessary materials such as wires, connectors, terminals,
junction boxes, and any specialized tools required for the job.
Safety: Ensure the power source is turned off to prevent electrical shock. Use appropriate
personal protective equipment (PPE) such as insulated gloves and safety glasses.
Routing wires: Route the wires according to the planned layout, ensuring they are neatly
organized and properly secured to prevent damage or interference.
Making connections: Strip the insulation from the ends of the wires and make connections
using connectors, terminals, or soldering, depending on the application. Follow the appropriate
wiring diagram or schematic.
Testing: Once the connections are made, test the circuit using a multimeter or other testing
equipment to verify proper continuity, voltage, and polarity.
Insulation: Insulate exposed wires and connections with electrical tape, heat shrink tubing, or
wire nuts to prevent short circuits and ensure safety.
Labeling: Label wires, components, and connections as needed for future reference and
troubleshooting.
Final inspection: Conduct a final inspection to ensure all connections are secure, wires are
properly routed, and safety measures are in place before restoring power.

FIG:4.22 WIRING OF CONTROLLER TO MOTOR

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 FIG:4.23 COMPLETE WIRING OF THE VEHICLE
8. CONTROLLER CONNECTIONS: In an electric vehicle conversion using a BLDC
(Brushless DC) motor, the controller connects several key components. Typically, it connects to
the battery pack for power, the motor for controlling speed and direction, and various sensors for
feedback such as throttle position, motor speed, and temperature. The specific connections may
vary depending on the controller and motor manufacturer, so consulting the respective datasheets
and wiring diagrams is crucial for accurate installation.
The specifications of an electric vehicle controller can vary depending on factors like the type of
motor (DC, AC, BLDC), power requirements, and vehicle size. However, here are some
common specifications you might find:
Voltage Range: The range of input voltage the controller can handle, typically matching the
battery voltage of the electric vehicle.
Current Rating: Maximum continuous current the controller can handle, which determines the
motor's torque output and acceleration capabilities.
Power Rating: The maximum power output of the controller, often calculated as the product of
voltage and current.
Motor Type Compatibility: Whether the controller is designed for DC, AC, or BLDC motors.
Control Interface: How the controller interfaces with the vehicle's throttle, brakes, and other

65
control systems (e.g., analog, digital, CAN bus).
Protection Features: Overcurrent protection, overvoltage protection, thermal protection, and
other safety mechanisms to protect the controller and the vehicle.
Efficiency: How efficiently the controller converts battery power into motor output power, often
expressed as a percentage.
Regenerative Braking: Whether the controller supports regenerative braking, which recaptures
energy during braking to recharge the battery.
Size and Weight: Physical dimensions and weight of the controller, important for fitting it into
the vehicle's space constraints.
Certifications: Compliance with safety and regulatory standards, such as CE, UL, or automotive-
specific certifications.

FIG:4.24 CONTROLLER CONNECTIONS

66
 FIG:4.25 CONTROLLER SPECIFICATIONS WITH CONNECTIONS
9. TESTIG OF ELECTRICAL COMPONENTS: Testing electrical components is crucial to
ensure they function properly and safely. Common methods include using a multimeter to
measure voltage, current, and resistance, as well as visual inspection for any signs of damage or
wear. Specific tests depend on the type of component and its intended use.
Testing electric vehicle components is essential for ensuring safety, reliability, and performance.
Here are some key uses:
Quality Assurance: Testing ensures that components such as batteries, motors, and control
systems meet quality standards before being integrated into vehicles.
Performance Optimization: By testing components under various conditions, engineers can
optimize their performance for factors like efficiency, range, and acceleration.
Safety Verification: Components must undergo rigorous testing to ensure they operate safely
under normal conditions and in emergencies, such as crash scenarios or extreme temperatures.
Durability Testing: Components are subjected to long-term stress tests to simulate real-world
usage and identify potential failure points, helping improve reliability and longevity.
Compatibility Testing: Testing ensures compatibility between different components and systems
within the vehicle, as well as with charging infrastructure and external devices.
Regulatory Compliance: Electric vehicles must meet regulatory requirements for emissions,

67
safety, and performance, which often necessitate extensive testing and certification processes.
Software Validation: Testing not only includes hardware but also software components such as
vehicle control systems, ensuring they function correctly and securely.
Prototype Validation: Testing helps validate the performance of prototype components and
systems, providing valuable feedback for refinement and optimization.
10. FIXING OF FINISHED SPROCKET TO VEHICLE: Fixing sprockets to a vehicle for
conversion typically involves determining the appropriate size and type of sprockets needed for
the conversion, ensuring they are securely mounted to the vehicle's transmission or axle, and
aligning them properly for efficient power transfer. Additionally, it's important to consider any
modifications needed to accommodate the new sprockets and ensure compatibility with the
vehicle's engine and drivetrain.
The gear ratio of chain sprockets refers to the ratio of teeth between the driving sprocket
(attached to the engine or motor) and the driven sprocket (attached to the wheel or axle). It
determines how many revolutions the driven sprocket makes for each revolution of the driving
sprocket. For example, if the driving sprocket has 10 teeth and the driven sprocket has 20 teeth,
the gear ratio would be 1:2, meaning the driven sprocket rotates twice for every rotation of the
driving sprocket. Gear ratios can be adjusted to optimize torque, speed, or efficiency depending
on the application. The process of fixing sprockets to a vehicle typically involves several steps:
Selecting Sprockets: Choose appropriate sprockets based on the desired gear ratio and
compatibility with the vehicle's engine, transmission, and axle.
Preparing the Vehicle: Ensure the vehicle is safely elevated or supported to allow access to the
transmission or axle area where the sprockets will be mounted.
Removing Existing Components: If necessary, remove any existing sprockets or components
that need to be replaced or modified for the conversion.
Mounting Sprockets: Securely mount the driving sprocket to the engine output shaft or motor
shaft using appropriate fasteners and ensuring proper alignment.
Aligning Sprockets: Align the driving sprocket with the driven sprocket on the wheel or axle to
ensure smooth power transfer and minimize wear on the chain.
Attaching Driven Sprocket: Securely attach the driven sprocket to the wheel hub or axle,
ensuring it is aligned properly with the driving sprocket.
Adjusting Chain Tension: Adjust the tension of the chain between the sprockets to ensure proper

68
engagement and minimize slack, which can cause issues with power transmission and wear.
Testing: Once the sprockets are fixed in place, test the vehicle to ensure everything is
functioning properly and make any necessary adjustments.
Final Inspection: Double-check all fasteners and connections to ensure they are tight and secure
before operating the vehicle.
Maintenance: Regularly inspect and maintain the sprockets, chain, and related components to
ensure optimal performance and longevity.

FIG:4.26 FRONT SPROCKET FIXING FIG:4.27 REAR SPROCKRT

69
 FIG:4.28 CHAIN FIXING TO THE SPROCKETS AND WHEELE BED
11. TESTING OF VEHICLE: Testing a converted vehicle involves evaluating its performance,
safety, and functionality after modifications, such as alternative fuel systems or accessibility
features. Tests may include road trials, emissions checks, and crash simulations to ensure
compliance with regulations and standards.
The purpose of testing a converted vehicle is to ensure that the modifications meet safety,
performance, and regulatory standards. It verifies that the vehicle operates correctly, is safe to
use, and meets the intended goals of the conversion, such as improved fuel efficiency, reduced
emissions, or enhanced accessibility.
When testing a converted vehicle, several key points should be considered:
Safety: Verify that the modifications don't compromise the safety of the vehicle or its occupants.
This includes structural integrity, crashworthiness, and proper functioning of safety systems.
Performance: Assess the performance of the vehicle after conversion, including acceleration,
handling, braking, and overall drivability. Ensure that it meets or exceeds performance
expectations.

70
Regulatory Compliance: Ensure that the converted vehicle complies with relevant regulations
and standards for emissions, safety, and vehicle operation in the intended market.
Reliability: Test the reliability of the modifications under various conditions to identify any
potential issues or failures that may arise during normal use.
Functionality: Verify that the converted vehicle functions as intended, including any added
features or systems such as alternative fuel systems, adaptive equipment, or customizations for
specific applications.
Durability: Assess the durability of the modifications to ensure they can withstand the rigors of
daily use over an extended period without premature wear or failure.
User Experience: Consider the overall user experience of operating the converted vehicle,
including comfort, convenience, and ease of use for drivers and passengers.
Environmental Impact: Evaluate the environmental impact of the conversion, such as changes
in emissions, energy efficiency, or sustainability compared to the original vehicle.
12. FINALLY THE VEHICLE CONVERSION IS COMPLETED: Congratulations on
completing the conversion from a petrol vehicle to an electric one! That's a
significant achievement.
Converting a petrol vehicle into an electric one serves several purposes:
Environmental impact: Electric vehicles produce fewer greenhouse gas emissions compared to
petrol vehicles, contributing to a cleaner environment and combating climate change.
Cost savings: Electric vehicles often have lower operating costs since electricity is typically
cheaper than petrol, and maintenance costs can be lower due to fewer moving parts in electric
motors.
Energy efficiency: Electric vehicles are more energy-efficient than petrol vehicles, utilizing
energy more effectively and potentially reducing overall energy consumption.
Sustainability: By reducing reliance on fossil fuels, electric vehicles contribute to a more
sustainable transportation system, helping to preserve finite resources for future generations.
Overall, converting to an electric vehicle aligns with efforts to create a more sustainable and
environmentally friendly transportation sector.

71
 CHAPTER 5
FAILURES AND CHALLENGES FACED
5.1 FAILURES OF THE CONVERSION PROCESS:
Converting anything, whether it's a file format or an idea, often involves challenges and failures.
Some common hurdles include compatibility issues, data loss, and learning curves with new
tools or concepts. Embracing these challenges as opportunities to learn and improve can lead to
eventual success.
While electric vehicles offer numerous benefits, there are some challenges and potential failures
associated with their widespread adoption:
Range Anxiety: Despite advancements in battery technology, many electric vehicles still have
limited range compared to traditional internal combustion engine vehicles. This can lead to range
anxiety, where drivers worry about running out of charge before reaching their destination.
Charging Infrastructure: The availability and accessibility of charging stations vary greatly
depending on location. Inadequate charging infrastructure can hinder the widespread adoption of
electric vehicles, especially in rural or less developed areas.
Battery Degradation: Over time, the performance and capacity of electric vehicle batteries
degrade. This can result in reduced driving range and increased charging times, ultimately
impacting the vehicle's overall lifespan and resale value.
High Initial Cost: Electric vehicles tend to have higher upfront costs compared to their gasoline
counterparts. While the total cost of ownership may be lower due to savings on fuel and
maintenance, the initial investment can be a barrier for many consumers.
Limited Model Options: While the number of electric vehicle models is growing, there are still
fewer options available compared to traditional gasoline-powered vehicles. Limited variety in
body styles, features, and price points may deter some consumers from switching to electric.
Supply Chain Issues: The production of electric vehicles relies on a complex global supply
chain, which can be vulnerable to disruptions. Shortages of key components such as lithium-ion
batteries or rare earth metals could impact production and increase costs.
Environmental Concerns: While electric vehicles produce zero tailpipe emissions, the
environmental impact of their production and disposal should be considered. Mining for raw
materials used in batteries, as well as the recycling or disposal of old batteries, can have

72
environmental consequences if not managed properly.
Addressing these challenges will be crucial for the continued growth and success of electric
vehicles in the future.
5.2 CHALLENGES OF THE CONVERSION PROCESS:
Converting a conventional vehicle to an electric one can pose several challenges:
Engineering Complexity: It requires expertise in electrical systems, motor mechanics, and
battery technology to ensure compatibility and performance.
Battery Integration: Finding the right battery pack that fits within the vehicle's constraints in
terms of size, weight, and power requirements can be challenging.
Motor Mounting: Installing the electric motor in a way that ensures proper alignment, cooling,
and integration with the vehicle's drivetrain can be tricky.
Regulatory Compliance: Adhering to safety and regulatory standards for electric vehicles,
including emissions regulations, can be complex and require certification.
Range and Performance: Ensuring the converted vehicle meets performance expectations in
terms of range, acceleration, and overall driving experience can be challenging, especially
considering factors like weight distribution and aerodynamics.
Cost: Converting a vehicle to electric power can be expensive, especially if high-quality
components are used. The initial investment may not always be recouped through fuel savings,
depending on the vehicle's usage.
Warranty and Support: Converting a vehicle may void its warranty, and finding support for
maintenance and repairs could be challenging, especially if specialized components are used.
Despite these challenges, converting a vehicle to electric power can be a rewarding project for
enthusiasts with the necessary skills and resources.
5.3 CHALLENGES FACED BY A TEAM WHILE DOING A PROJECT:
1. Sprocket Failure
2. Battery Connections Failure
3. Wiring Of Vehicle Failure
4. Charging Circuit Failure
5. Throttle Failure
1. SPROCKET FAILURE: Sprocket failure in an electric vehicle conversion could be caused
by various factors such as improper sizing, material fatigue, misalignment, or excessive torque.

73
It's essential to assess the specific circumstances of the failure to determine the root cause and
prevent it from happening again.
The specifications of sprocket failure in an electric vehicle conversion can vary depending on factors
such as the type of vehicle, powertrain configuration, and usage conditions. However, some
common specifications to consider when analyzing sprocket failure include:
Sprocket material: Determine the material composition of the sprocket, such as steel, aluminum, or
composite materials, as this can affect its strength and durability.
Sprocket size and pitch: Identify the size and pitch of the sprocket teeth to ensure proper meshing
with the chain or belt drive system.
Torque rating: Evaluate the maximum torque that the sprocket is designed to handle to avoid
overloading and premature failure.
Alignment: Check the alignment of the sprocket with other components in the drivetrain to prevent
excessive wear and stress on the sprocket teeth.
Fatigue resistance: Assess the sprocket's resistance to fatigue and cyclic loading, especially in high-
torque applications or under harsh operating conditions.
Maintenance history: Review the maintenance history of the sprocket, including inspection
intervals and any previous instances of wear or damage.
By examining these specifications and considering the specific circumstances of the sprocket failure,
you can better understand the root cause and implement measures to prevent future failures in
your electric vehicle conversion.

FIG:5.1 GROOVE FAILURE

74
2. BATTERY CONNECTIONS FAILURE: When experiencing battery connection failure in
an electric vehicle conversion, it's crucial to check the wiring connections thoroughly. Ensure all
connections are secure and free from corrosion. Additionally, verify that the battery management
system (BMS) is functioning correctly to monitor and balance the cells. If the issue persists,
consulting with a professional electrician or automotive technician experienced in EV
conversions is advisable to diagnose and resolve the problem safely.
Connecting the battery terminals incorrectly, especially in an electric vehicle conversion, can be
dangerous and damaging. Reverse polarity can lead to short circuits, damaging the battery,
electrical components, and potentially causing fire hazards. It's crucial to disconnect the battery
immediately and correct the connections to match the correct polarity. Then, carefully inspect all
components for any signs of damage before attempting to power on the vehicle again. If unsure,
seeking assistance from a professional electrician or automotive technician experienced in EV
conversions is recommended to ensure safety and proper functioning.
If you've mistakenly connected batteries in parallel incorrectly, it's essential to rectify the
situation promptly to avoid damage to the batteries or electrical components. First, disconnect
the batteries to prevent any further issues. Then, carefully assess the connections to identify the
incorrect wiring. Ensure that positive terminals are connected to positive terminals and negative
terminals to negative terminals. Double-check the connections against a reliable wiring diagram
if available. Once corrected, verify the connections and test the system carefully to ensure proper
functionality before using the electric vehicle again. If unsure, seek assistance from a
professional electrician or someone experienced in electrical systems to avoid potential hazards.

75
 FIG:5.2 BATTERY WITH PARALLEL CONNECTION FAILURE
3. WIRING OF VEHICLE FAILURE: The wiring in an electric vehicle conversion is crucial
for ensuring proper functioning and safety. Failures in the wiring can occur due to various
reasons such as inadequate insulation leading to short circuits, improper connections causing
voltage drops or intermittent connections, and using inappropriate gauge wires for the load
requirements. It's essential to follow wiring diagrams meticulously, use high-quality materials,
and double-check connections to minimize the risk of failures. Regular maintenance and
inspections can also help identify and prevent potential wiring issues.
Converting a vehicle to electric power can be a complex process. Here are some common
challenges:
Battery Integration: Finding the right type, size, and configuration of batteries to fit the vehicle's
space and weight requirements.
Motor Compatibility: Ensuring the electric motor is compatible with the vehicle's transmission
and drivetrain.
Charging Infrastructure: Availability of charging stations and compatibility with the vehicle's
charging system.
Safety Concerns: Ensuring proper insulation and protection against electrical hazards, as well as
crash safety standards compliance.
Regulatory Compliance: Adhering to legal requirements and obtaining necessary permits for the
conversion.

76
Range Anxiety: Balancing the trade-off between battery range and vehicle weight/cost.
Cost: Electric vehicle components can be expensive, and the overall conversion cost can be high.
Maintenance and Support: Availability of trained technicians and spare parts for electric
components.
Performance Optimization: Tuning the electric powertrain for optimal performance and
efficiency.
Weight Distribution: Ensuring the vehicle maintains proper weight distribution for
handling and stability.
4. CHARGING CIRCUIT FAILURE: Troubleshooting a charging circuit issue in an electric
vehicle conversion can be complex. Have you checked the connections, fuses, and the integrity
of the components involved? It could be a wiring issue, a faulty component, or a problem
with the control unit. If the charging circuit is not working in an electric vehicle conversion, the
vehicle will not be able to charge its batteries. As a result, the vehicle will have limited or no
range, as it relies on the batteries being charged to function. It's crucial to diagnose and fix the
charging circuit issue to ensure the vehicle can operate properly.
The properties or symptoms of a charging circuit failure in an electric vehicle conversion can
include:
No Charging: The vehicle's batteries do not charge when connected to a charging station.
Error Messages: The vehicle's onboard systems may display error codes or messages related to
charging.
No Power Output: Testing may reveal that the charging circuit is not supplying power to the
batteries.
Overheating: Components of the charging circuit may overheat due to excessive current flow or
a short circuit.
Burnt Smell: A burnt smell near the charging components could indicate a failure or malfunction.
Fuses Blown: Fuses in the charging circuit may blow due to overcurrent or a fault.
Inability to Start: In severe cases, the vehicle may not start at all due to depleted batteries.
These are some common indicators of a charging circuit failure, but the specific symptoms can
vary depending on the nature of the issue and the design of the conversion.
5. THROTTLE FAILURE: If the throttle of a vehicle fails while it's in operation, it could lead
to loss of control over acceleration. This can be very dangerous and may require immediate
action
77
to safely stop the vehicle and address the issue. In an electric vehicle conversion, the throttle controls
the motor's speed and acceleration. If the throttle fails while the vehicle is in operation, it could
result in loss of control over acceleration, similar to a traditional vehicle. However, since electric
vehicles have different systems than internal combustion engine vehicles, the specific
implications and troubleshooting steps may differ. It's crucial to consult with a qualified
technician or engineer familiar with electric vehicle conversions to diagnose and address the
issue safely.
Throttle failure in an electric vehicle conversion can manifest in various ways, including:
Loss of motor response: The throttle may become unresponsive, leading to no acceleration or
deceleration despite pressing the accelerator pedal.
Sudden acceleration or deceleration: The throttle may get stuck in a certain position, causing the
vehicle to accelerate or decelerate unexpectedly.
Erratic behavior: The throttle response may become erratic, with unpredictable changes in
acceleration or deceleration.
Inability to maintain speed: The vehicle may struggle to maintain a consistent speed, even when
the throttle input remains constant.
Dashboard warning lights: Some electric vehicles may have warning lights or error codes
indicating throttle-related issues.
Addressing throttle failure in an electric vehicle conversion typically requires thorough diagnostics
to identify the root cause, which could involve examining the throttle sensor, wiring, or
controller. It's essential to address throttle issues promptly to ensure safe operation of the vehicle.
Consulting with experienced professionals or technicians familiar with electric vehicle systems is
advisable for proper diagnosis and resolution.
In any case, when the throttle fails in an electric scooter, it's crucial for the rider to safely bring the
scooter to a stop and assess the situation. Continuing to ride with a faulty throttle can be
dangerous and may lead to accidents. Seeking assistance from a qualified technician or electric
scooter repair specialist is advisable to diagnose and fix the throttle issue promptly.

78
 CHAPTER-6
RESULTS AND DISCUSSIONS
The results and discussions of electric vehicle (EV) conversion typically focus on factors like

performance, efficiency, cost-effectiveness, and environmental impact. Researchers and enthusiasts

often analyze aspects such as the range of the converted vehicle, battery life, charging infrastructure,

and the overall driving experience compared to traditional gasoline vehicles. Discussions might also

cover challenges like battery technology limitations, conversion costs, and regulatory hurdles.

Overall, the goal is to assess the feasibility and benefits of converting internal combustion engine

vehicles to electric power.

 Top speed of 45 Kmph was achieved on a level road.

 The range of bike is 70-80 Km after full charge.

 A BMS and lithium Ion battery can be added for more range and reduced weight.

 Bike was tested successfully for light daily use.

 Battery charging takes around 6 hours for full charge.

TABLE:6.1 PERFORMANCE RANGE OF COMMERCIALLY AVAILABLE ELECTRIC

VEHICLES.
Speed 45 km/h
Maximum speed 45 to 50kmph
Batteries Charging time 5 - 6 hours
Power consumption 750W
On-board power supply 48V- 1000W

Travel range 16–80 km (Full charge)

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TABLE:6.2 SPEED RANGES OF ELECTRIC BIKE ON DIFFERENT ROAD
CONDITIONS

Conditions On highway road On Off road On Sand road

45km/hr 35km/hr 32km/hr
one person on
the bike
When two 43km/hr 31km/hr 29km/hr
persons on the
bike

GRAPH:6.1 SPEED RANGE ON DIFFERENT CONDITIONS BY GRAPH

80
TABLE:6.3 EFFICIENCY OF THE BIKE WITH DIFFERENT LOADS

Conditions On highway road On Off road On Sand road

70km 67km 53km
one person
on the
bike
When two 65km 62km 48km
persons on
the bike

GRAPH:6.2 EFFICIENCY ON DIFFERENT CONDITIONS BY GRAPHICAL

MENTHOD

81
 CHAPTER-7
CONCLUSION
The conclusion of the electric vehicle conversion process usually involves summarizing the

findings from the results and discussions. It may highlight the feasibility and benefits of EV

conversion, such as reduced emissions, lower operating costs over time, and potentially

improved performance. However, it might also address challenges like high initial conversion

costs, limited range, and the need for infrastructure support. Ultimately, the conclusion aims to

provide insights into the viability of EV conversion as a sustainable transportation solution and

may suggest areas for further research or improvement. Furthermore, the performance of the

vehicle can be enhanced by selecting a high torque and power-rated electric motor which is

better than the existing motor utilized in this work but increases the cost of the vehicle. In a

country like Ethiopia, the unavailability of charging stations is also the main concern for the

adoption of solar electric vehicles. The major challenge in vehicle conversion work is that the

weight of the vehicle will be heavy because the existing chassis structure is used which is the

heaviest part of the vehicle. Therefore, it is very difficult to achieve the optimum center of

gravity of the vehicle after the engine and its associated components are replaced with the

battery, DC motor, and other electrical equipment.

82
 CHAPTER-8
REFERENCES
[1] Aikenhead, G. S. (2011). Bicycle Applications for On-Board Solar Power Generation. 9,10.
[2] Barve, D. S. (2016). Design and Development of Solar Hybrid Bicycle. International Journal
of Current Engineering and Technology, 377,378,379,380.
[3] Barve, D. S. (March 2016). Design and Development of Solar Hybrid Bicycle. International
Journal of Current Engineering and Technology, 378,379.
[4] Barve, D. S. (March 2016). Design and Development of Solar Hybrid Bicycle. International
Journal of Current Engineering and Technology, 380.
[5] FOGELBERG, F. (2014). Solar Powered Bike Sharing System. Goteberg, Sweden: Viktoria
Swedish ICT.
[6] FOGELBERG, F. (2014). Solar Powered Bike Sharing System with. Goteborg, sweden:
Viktoria Swedish ICT.
[7] GOODMAN, J. D. (2010, Jan 31). An Electric Boost for Bicyclists. The New York Times.
[8] Prof. Palak Desai, P. D. (June 2016). Design and Fabrication of Solar Tri Cycle. International
Journal of Engineering Sciences & Research, 664.
[9] Hameed Majeed Saber and Deepak Lal, Assessment of Solar Energy Distribution For
Installing Solar Panels Using Remote Sensing & GIS Techniques, International Journal of
Advanced Research in Engineering and Technology (IJARET) Volume 5, Issue 10, October
(2014), pp. 157- 164.
[10] Srijan Manish, Jitendra Kumar Rajak, Vishnu Kant Tiwari and Rakesh, Quad Bike Design
And Simulation: A Pre-Manufacturing Methodology, International Journal of Advanced
Research in Engineering and Technology (IJARET)Volume 5, Issue 6, June (2014), pp. 68- 76
[11] [Link]. (April 2015). Novel Design of Solar Electric Bicycle with Pedal. International
Journal & Magazine of Engineering, 108.

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