Hello Fellow BHPians,
Background:
Recently I had seen a lot of videos online where people started converting ICE vehicles to EV. The launch of Nexon EV & MG ZS EV has spiced up the EV market and also sparked an idea in my mind.
Idea:
One of my friend owns a factory in Hyderabad and he owns around 4 Tata Ace vehicles for goods delivery. I approached him with this idea to convert his Ace pickup truck to EV and he was excited as well, as he was fed up with diesel and other maintenance costs. He proposed to start the conversion with 1 vehicle and if it is a success, then we will convert the rest of them.
Problem:
There are a lot of startup's in India like e-Trio and BharatMobi, which by coincidence are all based in Hyderabad and are in to retrofitting ICE to EV vehicles, unfortunately they currently do not offer any readymade kits for Tata Ace vehicle.
One fine day me and my friend started visiting local mechanics and the biggest road block here is, almost all of the mechanics are clueless on how to do it. They have no idea how much capacity motor and battery is required or where to start.
Solution:
I decided to take things in to my own hands and I am planning to tie up with some local experienced mechanics and electricians to get the ICE engine removed and retro fit it with Electric motor. This way I will learn something new and can test the waters myself.
So I have decided to start a thread here to capture my journey of EV conversion and I will be updating this thread regularly on the progress, conversion process, cost, road blocks etc. Hopefully this will help others are who are planning something similar and are looking for guidance and assistance.
I deeply value inputs and suggestions from fellow BHPians on this project.
Steps:
- Identify the vehicle
- Calculate the motor power requirements
- Calculate the battery requirements
- Actual Conversion
- Price Estimates
- Testing
- Re-engineering (if required)
Identify the vehicle:
This step is done. Tata Ace Diesel has been selected for this project. A bit of technical specifications of the vehicle below
Engine:
Model :TATA 275 IDI Diesel BS IV
Type :4 stroke, naturally aspirated, indirect injection diesel engine
Max. output :11.3 kW (16 HP) @ 3200 r/min
Max. torque :37.5 Nm @ 2000 r/min
Displacement :702 cm3
Special items :Catalytic converter (only in BS IV)
Dimensions:
- Length (mm) :3800
- Width (mm) :1500
- Height (mm) :1845
- Wheelbase (mm) :2100
- Front Wheel Gauge (mm) :1300
- Rear Wheel Gauge (mm) :1320
- Loading Deck Length (mm) :2140
- Loading Deck Width (mm) :1430
- Height of Side Panels (mm) :300
- Min. Turning Circle Diameter (mm) :8600
Weight:
- Max. GVWR : 1550 kg
- Kerb Weight : 840 kg
- Seating capacity : Driver + 1
Source -
https://ace.tatamotors.com/tata-truc...fications.aspx Calculate the motor power requirements:
Weight = 840 kgs
Length = 3800 mm = 3.8m
Width = 1500 mm = 1.5m
Height = 1845 mm
Max Speed = 50
Efficiency = 85%
Wheel Size = 13 inches
Wheel Radius = 6.5 inches = 0.165
Linear Distance Traveled = 2πr = 2 x 3.14 x 0.165 = 1.0362
Speed = 50000/3600 = 13.88 m/sec
RPM = 50000/(1.0362*60)=804.24
Power=[(Mass in kg) x (Velocity in G) x (Velocity in m/s) x (Rr)] + [(Air Density x Cd x Area (Length x Width) x Velocity to power of 3)]
= (840*9.8*13.88*0.01) + (0.6465*0.6*5.7*2674)
= 1,142.6 + 5,912.29
= 7,054 watts
Drag coefficient Cd source -
https://en.wikipedia.org/wiki/Drag_coefficient
As per above calculations, we have concluded that we would require approximately 7,054 watts power motor. However, currently in market we can get either 6,000 watts or 8,000 watts kit, so we decided to procure 8,000 watts motor kit.
We contacted a supplier in New Delhi from Karol Bhag area and got a quotation of around 1 lakh for the electric motor, controller, wiring and charger (battery excluded), as it is a big investment, we wanted to be 100% sure before we proceed with the motor purchase
Anyone any thoughts on the above calculations? We will double check the calculations and will take thoughts from other mechanics and electricians as well before we proceed.
Mod Note: Please feel free to move the thread to appropriate thread.