ABSTRACT

Practice makes a man perfect. A student gets theoretical knowledge from classroom and gets
practical knowledge from industrial training. When these two aspects of theoretical
knowledge and practical experience together then a student is fully equipped to secure his
best.

In conducting the project study in an industry, students get exposed and have knowledge of
real situation in the work field and gains experience from them. The object of the summer
training is to provide an opportunity to experience the practical aspect of technology in any
organization. It provides a chance to get the feel of the organization and its function.

During my industrial training, in the first day, I was given a task to learn about kitting system
that I must know all the tools which is necessary for every electrical engineer. Indeed, I had to
prepare a set of tools by according tooling list. After a week, I was given a manual book to
learn how to operate those machines.

After several weeks, I was starting to learn some new things. There were some technical
skills, tooling maintenance and drive functions. During the training period I learn about my
field’s fresh thing electric car. I also learnt about industry automation with drive and control
logic development of EV and Conversion from conventional to EV. In the duration of
Training, I learnt so much fresh things of my field like Development of EV, Conversion of
Conventional Vehicle to EV etc.

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 Chapter-1

INTRODUCTION

1.1 Overview
The term “EV” refers to an electric vehicle. EVs are automobiles that run entirely or
primarily on electricity. An electric vehicle (EV) is a type of vehicle that uses one or more
electric motors for propulsion, as opposed to traditional internal combustion engines (ICEs)
that rely on gasoline or diesel fuel. EVs are designed to be powered by electricity, which is
typically stored in batteries or other energy storage devices.

Electricity or renewable energy is used to power electric vehicles. This is one of the most
important advantages of Electric Vehicle. They don’t produce any emissions or exhale any
dangerous gases. As a result, they are environmentally friendly vehicles that contribute to the
reduction of ever-increasing air pollution. Electric vehicles have low running costs as they
have fewer moving parts for maintenance and also very environmentally friendly as they use
little or no fossil fuels (petrol or diesel). While some EVs used lead acid or nickel metal
hydride batteries, the standard for modern battery electric vehicles is now considered to be
lithium-ion batteries as they have a greater longevity and are excellent at retaining energy,
with a self-discharge rate of just 5% per month. Compared to an ICE vehicle, an electric
vehicle is approximately 3 times more efficient. Using less energy to power your vehicle also
helps to reduce costs.

Typically, an electric car would have a running cost of Rs 1.2-1.4 per km, while petrol prices
hover around Rs 9-10/km. If you factor that into the long-term, say 6 to 8 years, the total you
would end up spending on battery charging would barely be over Rs 1 lakh due to the low
electricity prices. On the other hand, a typical fuel run car would require around Rs 4.5 lakhs
worth of petrol/diesel for the same time duration. Simply put, electric cars are way cost-
efficient in the long run even if they cost more to buy.

An electric car provides a smooth and silent experience while driving, as the only moving
parts are the electric motors. All the energy from the battery is delivered to these motors,
which results in high torque and pickup speeds; in contrast, in IEC cars, the energy has to be
processed through gears, clutches, and the engine for the car to move.

2
This way, an electric car has relatively better performance than a fossil fuel-run car and is
able to run more efficiently due to fewer moving parts in it. Generally, the battery capacity on
an EV is equivalent to the size of a fuel tank, which means the range it would provide is
sufficient for more or less one day of commute around the city, but again it also varies from
car to car (and their battery capacities). Also, the fact the EV charging stations aren’t as
widespread as petrol pumps is a disadvantage for now. Additionally, electric cars can take a
long time to top up the battery, depending on the source; that is not a concern if you have a
petrol/ diesel car. All in all, if you hit the road for long journeys every now and then, a petrol
or diesel car is a better pick, while for daily city commutes an electric car has got you
covered.

An electric vehicle charging station is equipment that connects an electric vehicle (EV) to a
source of electricity to recharge electric cars, neighbourhood electric vehicles and plug-in
hybrids. Some charging stations have advanced features such as Smart metering, cellular
capability and network connectivity, while others are more basic.

Fig: -1.1 Electric Car (KIA)

1.2 Introduction to Electric Vehicle Technology:

An electric vehicle is the one which uses traction motors for propulsion which get power
from either external storage or internal storage system within them, which is manufactured

3
for use on public roads. EVs first came into existence in the mid-19th century, when
electricity was among the preferred methods for propulsion, providing a level of comfort and
ease of operation that could not be achieved by of the time. were the dominant propulsion
method for and for about 100 years, but electric power remained commonplace in other
vehicle types, such as trains and smaller vehicles of all types. In the 21st century, EVs have
seen a resurgence due to technological developments, and an increased focus on and the
potential reduction of describes electric vehicles as one of the 100 best contemporary
solutions.
Instead of a traditional internal combustion engine, EVs have an electric motor. Thus,
conventional fuel (petrol/diesel) is replaced by electric energy. Electrical energy is converted
into mechanical energy by electric motors. EVs function like automatic vehicles. Electric
Vehicles using BEV technology run entirely on a battery-powered electric drivetrain. The
electricity used to drive the vehicle is stored in a large battery pack which can be charged by
plugging into the electricity grid.

Fig: -1.2 Electric Vehicle Technology developments

1.3 Benefits of EVs in India

1.3.1 Lower running costs

Since you are not paying for petrol or diesel to keep your EV running, you save a lot of
money on fuel. The cost to charge an electric vehicle compared to the price of petrol or diesel

4
is substantially low. You can reduce the electricity cost further by utilising renewable energy
sources such as solar.

1.3.2 Low maintenance costs

Petrol or diesel-powered vehicles require regular maintenance since they have multiple
moving parts. That’s not the case with electric vehicles since they have comparatively lesser
moving parts. This means that your electric car is likely to have lower maintenance costs in
the long run.

1.3.3 Tax and financial benefits

With India embracing the inclusion of EVs, the government offers several policies and
incentives to encourage the usage of such vehicles. For instance, the registration fees and
road tax on purchasing EVs are lesser than ICE vehicles.

1.3.4 Better performance

In the past, EVs were seen as impractical. However, that has changed over the years, with
manufacturers offering well-designed and good-looking EVs. Even the performance of EVs
has changed for the better. Electric Vehicles are lighter in weight, and their acceleration is
impeccable compared to fuel-powered vehicles.

1.3.5 Zero tailpipe emissions

EVs emit zero tailpipe emissions, helping reduce the carbon footprint. You can further reduce
your carbon footprint by utilising renewable energy to charge your EV.

1.3.6 Easy to drive and quiet

With lesser moving parts and uncomplicated controls, EVs are easy to drive. Also, you can
plug such a vehicle into a public or home charging station when you want to charge it. They
are also quiet, thereby reducing the sound levels that fuel-powered vehicles generate.

5
1.3.7 Convenience of charging at home

There is no need to find the nearest petrol station to fill fuel. Charge your EV at home and get
moving. With new-age charging technology, you can charge an EV quickly or even take
advantage of battery swapping services to keep driving without worrying about the
availability of conventional fuel.

1.3.8 No fuel, no emissions

One of the most significant advantages of EVs is their impact on our environment. Pure EVs
have zero tailpipe emissions, which reduces air pollution. Since the electric motor of the EV
operates on a closed circuit, it does not emit any harmful gases. Pure electric cars do not
require petrol or diesel, which is excellent for the environment.

1.3.9 Spacious cabin and more storage

With less moving parts, electric vehicles offer the opportunity to convert these spaces into
storage and offer larger cabin room. You can also find storage spaces under the hood since
the conventional ICE is no more there. EV motors and batteries do not take a lot of space
compared to fuel-powered vehicles.

1.3.10 They are future proof

With several countries pledging to gradually reduce their dependence on petrol and diesel
(fossil fuels), EVs are considered a sustainable alternative.

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 Chapter-2

HISTORY OF THE ELECTRIC VEHICLE

2.1 Electric Model Cars

Designs of electric motors by individuals such as Benjamin Franklin led to ideas for electric
vehicles. The invention of the first model electric vehicle is attributed to various people. In
1828, the Hungarian priest and physicist Ányos Jedlik invented an early type of electric
motor, and created a small model car powered by his new motor. Between 1832 and 1839,
Scottish inventor Robert Anderson also invented a crude electric carriage. In 1835, Professor
Sibrandus Stratingh of Groningen, the Netherlands and his assistant Christopher Becker from
Germany also created a small-scale electric car, powered by non-rechargeable primary cells.

2.2 Electric Locomotives

In 1834, Vermont blacksmith Thomas Davenport built a similar contraption which operated
on a short, circular, electrified track. The first known electric locomotive was built in 1837, in
Scotland by chemist Robert Davidson of Aberdeen. It was powered by galvanic cells
(batteries). Davidson later built a larger locomotive named Galvani, exhibited at the Royal
Scottish Society of Arts Exhibition in 1841. The 7,100 kg (7-long-ton) vehicle had two direct-
drive reluctance motors, with fixed electromagnets acting on iron bars attached to a wooden
cylinder on each axle, and simple commutators. It hauled a load of 6,100 kg (6 long tons) at
6.4 km/h (4 mph) for a distance of 2.4 km (1.5 mi). It was tested on the Edinburgh and
Glasgow Railway in September of the following year, but the limited power from batteries
prevented its general use. It was destroyed by railway workers, who saw it as a threat to their
security of employment.

A patent for the use of rails as conductors of electric current was granted in England in 1840,
and similar patents were issued to Lilley and Colten in the United States in 1847. The first
battery rail car was used in 1887 on the Royal Bavarian State Railways.

2.3 Golden age

Interest in motor vehicles increased greatly in the late 1890s and early 1900s. Electric battery-
powered taxis became available at the end of the 19th century. In London, Walter Bersey

7
designed a fleet of such cabs and introduced them to the streets of London in 1897. They
were soon nicknamed "Hummingbirds" due to the idiosyncratic humming noise they made. In
the same year in New York City, the Samuel's Electric Carriage and Wagon Company began
running 12 electric hansom cabs. The company ran until 1898 with up to 62 cabs operating
until it was reformed by its financiers to form the Electric Vehicle Company.

Electric vehicles had a number of advantages over their early-1900s competitors. They did
not have the vibration, smell, and noise associated with gasoline cars. They also did not
require gear changes. (While steam-powered cars also had no gear shifting, they suffered
from long start-up times of up to 45 minutes on cold mornings.) The cars were also preferred
because they did not require a manual effort to start, as did gasoline cars which featured a
hand crank to start the engine.

Electric cars found popularity among well-heeled customers who used them as city cars,
where their limited range proved to be even less of a disadvantage.

Acceptance of electric cars was initially hampered by a lack of power infrastructure. In the
United States by the turn of the century, 40 per cent of automobiles were powered by steam,
38 per cent by electricity, and 22 per cent by petrol. A total of 33,842 electric cars were
registered in the United States, and the U.S. became the country where electric cars had
gained the most acceptance. Most early electric vehicles were massive, ornate carriages
designed for the upper-class customers that made them popular. They featured luxurious
interiors and were replete with expensive materials. Electric vehicles were often marketed as
luxury cars for women, which may have generated a stigma among male consumers. Sales of
electric cars peaked in the early 1910s. There were over 300 listed manufacturers who
produced a vehicle in the United States until 1942.

In 1910s, The Standard Electric used Westinghouse electric motors and claimed to have a
range of 110 miles on a charge. It was operated by a tiller from the left-hand side. The
controller had six forward speeds, and had a top speed of 20-mph. The model M was a closed
model Coupe or open Runabout, and priced from $1,785 to $1,900.

To overcome the limited operating range of electric vehicles, and the lack of recharging
infrastructure, an exchangeable battery service was first proposed as early as 1896. The
concept was first put into practice by Hartford Electric Light Company through the GeVeCo

8
battery service and was initially available for electric trucks. The vehicle owner purchased the
vehicle from General Vehicle Company (GVC, a subsidiary of the General Electric
Company) without a battery and the electricity was purchased from Hartford Electric through
an exchangeable battery. The owner paid a variable per-mile charge and a monthly service fee
to cover the maintenance and storage of the truck. Both vehicles and batteries were modified
to facilitate a fast battery exchange. The service was provided between 1910 and 1924 and
during that period covered more than 6 million miles. Beginning in 1917 a similar successful
service was operated in Chicago for owners of Milburn Wagon Company cars who also could
buy the vehicle without the batteries.

In New York City, in the pre-World War I era, ten electric vehicle companies banded together
to form the New York Electric Vehicle Association. The association included manufacturers
and dealers, among them General Motors' truck division, and the aforementioned General
Vehicle division of General Electric, which claimed to have almost 2,000 operating vehicles
in the metropolitan region. When opening their flagship department store, Lord and Taylor
boasted of its electric vehicle fleet numbering 38 trucks – and the conveyor system to
efficiently load and unload goods.

Fig: -2.1 Thomas Edison and an electric car in 1913

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2.3.1 1920s–1950s:

After enjoying success at the beginning of the 20th century, the electric car began to lose its
position in the automobile market. A number of developments contributed to this situation.
By the 1920s an improved road infrastructure improved travel times, creating a need for
vehicles with a greater range than that offered by electric cars. Worldwide discoveries of large
petroleum reserves led to the wide availability of affordable petrol, making petrol-powered
cars cheaper to operate over long distances. Electric cars were limited to urban use by their
slow speed (no more than 24–32 km/h or 15–20 mph) and low range (50–65 km or 30–40
miles), and gasoline cars were now able to travel farther and faster than equivalent electrics.

Gasoline cars also overcame much of their negatives compared to electrics, in several areas.
Whereas ICE cars originally had to be hand-cranked to start – a difficult and sometimes
dangerous activity – the invention of the electric starter by Charles Kettering in 1912
eliminated the need of a hand starting crank. Further, while gasoline engines are inherently
noisier than electric motors, the invention of the muffler by Milton O. Reeves and Marshall T.
Reeves in 1897 significantly reduced the noise to tolerable levels. Finally, the initiation of
mass production of gas-powered vehicles by Henry Ford brought their price down. By
contrast, the price of similar electric vehicles continued to rise; by 1912, an electric car sold
for almost double the price of a gasoline car.

Most electric car makers stopped production at some point in the 1910s. Electric vehicles
became popular for certain applications where their limited range did not pose major
problems. Forklift trucks were electrically powered when they were introduced by Yale in
1923. In Europe, especially the United Kingdom, milk floats were powered by electricity, and
for most of the 20th century the majority of the world's battery electric road vehicles were
British milk floats. Electric golf carts were produced by Lektro as early as 1954. By the
1920s, the early heyday of electric cars had passed, and a decade later, the electric automobile
industry had effectively disappeared.

Years passed without a major revival in the use of electric cars. Fuel-starved European
countries fighting in World War II experimented with electric cars such as the British milk
floats and the French Bréguet Aviation car, but overall, while ICE development progressed at
a brisk pace, electric vehicle technology stagnated. In the late 1950s, Henney Coachworks

10
and the National Union Electric Company, makers of Exide batteries, formed a joint venture
to produce a new electric car, the Henney Kilowatt, based on the French Renault Dauphine.
The car was produced in 36-volt and 72-volt configurations. The 72-volt models had a top
speed approaching 96 km/h (60 mph) and could travel for nearly an hour on a single charge.
Despite Kilowatt's improved performance with respect to previous electric cars, it was about
double the cost of a regular gasoline-powered Dauphine, and production ended in 1961.

2.3.2 1960s–1990s:

In 1959, American Motors Corporation (AMC) and Sonotone Corporation announced a joint
research effort to consider producing an electric car powered by a "self-charging" battery.
AMC had a reputation for innovation in economical cars while Sonotone had technology for
making sintered plate nickel-cadmium batteries that could be recharged rapidly and weighed
less than traditional lead-acid versions. That same year, Nu-Way Industries showed an
experimental electric car with a one-piece plastic body that was to begin production in early
1960.

In the mid-1960s a few battery-electric concept cars appeared, such as the Scottish Aviation
Scamp (1965), and an electric version of General Motors gasoline car, the Electrovair (1966).
None of them entered production. The 1973 Enfield 8000 did make it into small-scale
production, 112 were eventually produced. In 1967, AMC partnered with Gulton Industries to
develop a new battery based on lithium and a speed controller designed by Victor Wouk. A
nickel-cadmium battery supplied power to an all-electric 1969 Rambler American station
wagon. Other "plug-in" experimental AMC vehicles developed with Gulton included the
Amitron (1967) and the similar Electron (1977).

On 31 July 1971, an electric car received the unique distinction of becoming the first crewed
vehicle to drive on the Moon; that car was the Lunar Roving Vehicle, which was first
deployed during the Apollo 15 mission. The "Moon buggy" was developed by Boeing and
GM subsidiary Delco Electronics (co-founded by Kettering) featured a DC drive motor in
each wheel, and a pair of 36-volt silver-zinc potassium hydroxide non-rechargeable batteries.

After years outside the limelight, the energy crises of the 1970s and 1980s brought about
renewed interest in the perceived independence electric cars had from the fluctuations of the
hydrocarbon energy market. However, vehicles such as the intensely-marketed Sinclair C5

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failed. General Motors created a concept car using another gasoline car as the base, the
Electrovette (1976). At the 1990 Los Angeles Auto Show, General Motors President Roger
Smith unveiled the GM Impact electric concept car, along with the announcement that GM
would build electric cars for sale to the public.

From the 1960s to the 1990s, a number of companies made battery electric vehicles converted
from existing manufactured models, often using gliders. None were sold in large numbers,
with sales hampered by high cost and a limited range. Most of these vehicles were sold to
government agencies and electric utility companies. The passage of the Electric and Hybrid
Vehicle Research, Development and Demonstration Act of 1976 in the US provided
government incentives for development of electric vehicles in the US. Electric Fuel
Propulsion Corporation (now Apollo Energy Systems) produced the Electrosport (a converted
AMC Hornet), the Mars I (a converted Renault Dauphine), and the Mars II (a converted
Renault R-10). Jet Industries sold the Electra-Van 600 (a converted Subaru Sambar 600), the
Electra-Van 750 (converted Mazda B2000/Ford Courier pickup trucks), the Electrica
(converted Ford Escort/Mercury Lynx cars) and the Electrica 007 (converted Dodge Omni
024/Plymouth Horizon TC3 cars). U.S. Electric car Corp., based in Massachusetts, sold the
Lectric Leopard, a converted Renault 5. Electric Vehicle Associates sold the Current Fare (a
converted Ford Fairmont) and the Change of Pace (a converted AMC Pacer). U.S. Electricar,
Inc., based in California, sold a converted Geo Prizm. Solectria Corporation (now Azure
Dynamics) sold the Solectria Force (a converted Geo Metro) and the E10 (a converted
Chevrolet S-10). Later, General Motors would also produce an electric S-10, the Chevrolet S-
10 EV, based on the General Motors EV1.

In the early 1990s, the California Air Resources Board (CARB), the government of
California's "clean air agency", began a push for more fuel-efficient, lower-emissions
vehicles, with the ultimate goal being a move to zero-emissions vehicles such as electric
vehicles. In response, automakers developed electric models, including the Chrysler TEVan,
Ford Ranger EV pickup truck, GM EV1 and S10 EV pickup, Honda EV Plus hatchback,
Nissan lithium-battery Altra EV miniwagon and Toyota RAV4 EV. The automakers were
accused of pandering to the wishes of CARB in order to continue to be allowed to sell cars in
the lucrative Californian market, while failing to adequately promote their electric vehicles in
order to create the impression that the consumers were not interested in the cars, all the while

12
joining oil industry lobbyists in vigorously protesting CARB's mandate. GM's program came
under particular scrutiny; in an unusual move, consumers were not allowed to purchase EV1s,
but were instead asked to sign closed-end leases, meaning that the cars had to be returned to
GM at the end of the lease period, with no option to purchase, despite lease interest in
continuing to own the cars. Chrysler, Toyota, and a group of GM dealers sued CARB in
Federal court.

After public protests by EV drivers' groups upset by the repossession of their cars, Toyota
offered the last 328 RAV4-EVs for sale to the general public for six months until 22
November 2002. Almost all other production electric cars were withdrawn from the market
and were in some cases seen to have been destroyed by their manufacturers. Toyota continues
to support the several hundred Toyota RAV4-EVs in the hands of the general public and in
fleet usage. GM famously de-activated the few EV1s that were donated to engineering
schools and museums.

Throughout the 1990s, interest in fuel-efficient or environmentally friendly cars declined

among consumers in the United States, who instead favored sport utility vehicles, which were
affordable to operate despite their poor fuel efficiency thanks to lower gasoline prices.
Domestic U.S. automakers chose to focus their product lines on truck-based vehicles, which
enjoyed larger profit margins than the smaller cars which were preferred in places like Europe
or Japan.

Most electric vehicles on the world roads were low-speed, low-range neighborhood electric
vehicles (NEVs). Pike Research estimated there were almost 479,000 NEVs on world roads
in 2011. As of July 2006, there were between 60,000 and 76,000 low-speed battery-powered
vehicles in use in the United States, up from about 56,000 in 2004. North America's top-
selling NEV is the Global Electric Motorcars (GEM) vehicles, with more than 50,000 units
sold worldwide by mid-2014. The world's two largest NEV markets in 2011 were the United
States, with 14,737 units sold, and France, with 2,231 units. Other micro electric cars sold in
Europe was the Kewet, since 1991, and replaced by the Buddy, launched in 2008. Also the
Th!nk City was launched in 2008 but production was halted due to financial difficulties.
Production restarted in Finland in December 2009. The Th!nk was sold in several European
countries and the U.S. In June 2011 Think Global filed for bankruptcy and production was
halted. Worldwide sales reached 1,045 units by March 2011. A total of 200,000 low-speed

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small electric cars were sold in China in 2013, most of which are powered by lead-acid
batteries. These electric vehicles are not considered by the government as new energy
vehicles due to safety and environmental concerns, and consequently, do not enjoy the same
benefits as highway legal plug-in electric cars.

2.3.3 2010s

The global stock of both plug-in hybrid electric vehicles (PHEVs) and battery electric
vehicles (BEVs) has grown steadily since the 2010s.The first Nissan Leaf delivered in the
U.S. went to a customer in the San Francisco Bay Area.

The Nissan Leaf, introduced in Japan and the United States in December 2010, became the
first modern all-electric, zero tailpipe emission five door family hatchback to be produced for
the mass market from a major manufacturer. As of January 2013, the Leaf is also available in
Australia, Canada and 17 European countries.

The Better Place network was the first modern commercial deployment of the battery
swapping model. The Renault Fluence Z.E. was the first mass production electric car enable
with switchable battery technology and sold for the Better Place network in Israel and
Denmark. Better Place launched its first battery-swapping station in Israel, in Kiryat Ekron,
near Rehovot in March 2011. The battery exchange process took five minutes. As of
December 2012, there were 17 battery switch stations fully operational in Denmark enabling
customers to drive anywhere across the country in an electric car. By late 2012 the company
began to suffer financial difficulties, and decided to put on hold the roll out in Australia and
reduce its non-core activities in North America, as the company decided to concentrate its
resources on its two existing markets. On 26 May 2013, Better Place filed for bankruptcy in
Israel.

The company's financial difficulties were caused by the high investment required to develop
the charging and swapping infrastructure, about US$850 million in private capital, and a
market penetration significantly lower than originally predicted by Shai Agassi. Less than
1,000 Fluence Z.E. cars were deployed in Israel and around 400 units in Denmark.

2.4 Executive Summary

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India today is one of the top ten automotive markets in the world and given its burgeoning
middle-class population with buying potential and the steady economic growth, accelerating
automotive sales is expected to continue. In the last couple of years, there has been a lot of
discussion around the prices of fuel - apart from the deregulation of petrol prices. Moreover,
the threat of disruption of supplies from the Middle-East has heightened the debate on energy
security and brought the focus on to alternate drivetrain technologies.

The potential for alternative technologies in automobiles such as electric vehicles (EV) in
India, as in the case of many other comparable markets, depends on improved battery
technologies, driving ranges, government incentives, regulations, lower prices and better
charging infrastructure.

There seems to be a lot of interest on the part of Internal Combustion Engine (ICE) based
manufacturers to adopt electric technology, not just supplemental to the ICE, but as a stand-
alone offering. There are also specialized EV manufacturers that have come up all over the
world.

While many of the factors that influence the EV market are understood intellectually, we
carried out a consumer survey to study perceptions and expectations of potential for
alternative technologies in automobiles such as electric vehicles (EV) and hybrid EV.

Assessing future demand for electric vehicles was somewhat challenging since it meant
testing consumer preferences for a product with which they are largely unfamiliar. For this
reason, we focused on uncovering consumers' familiarity with EV technologies and products;
with their opinions around price, brand, range, charging, the infrastructure, and the cost of
ownership; and with the consumer's imagined "fit" of an EV in his or her lifestyle given a
range of demographic parameters.

2.5 Automotive Industry in India:

The automotive industry in India is one of the larger markets in the world and had previously
been one of the fastest growing globally, but is now seeing flat or negative growth rates.
India's passenger car and commercial vehicle manufacturing industry is the sixth largest in
the world, with an annual production of more than 3.9 million units in 2011.

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Chennai is home to around 35-40% of India's total automobile industry and for this reason it
is known as the Detroit of Asia. It is on the way to becoming the world's largest Auto hub by
2016 with a capacity of over 3 million cars annually. The majority of India's car
manufacturing industry is based around three clusters in the south, west and north. The
southern cluster consisting of Chennai is the biggest with 35% of the revenue share. The
western hub near Mumbai and Pune contributes to 33% of the market and the northern cluster
around the National Capital Region contributes 32%. Chennai, with the India operations of
Ford, Hyundai, Renault, Mitsubishi, Nissan, BMW, Hindustan Motors, Daimler

Chennai accounts for 60% of the country's automotive exports. Gurgaon and Manesar in
Haryana form the northern cluster where the country's largest car manufacturer, Maruti
Suzuki, is based. The Chakan corridor near Pune, Maharashtra is the western cluster with
companies like General Motors, Volkswagen, Skoda, Mahindra and Mahindra, Tata Motors,
Mercedes Benz, Land Rover, Jaguar Cars, Fiat and Force Motors having assembly plants in
the area. Nashik has a major base of Mahindra & Mahindra with a UV assembly unit and an
Engine assembly unit.

Table 2.1: - Difference Between Electric Vehicle and ICE

Vehicle Type Electric Vehicle Internal Plug in Hybrid Hybrid

Combustion
(EV) (PHEV) (HV)

Energy Source Electric Only Gasoline Main: Electric Main: Gasoline

Only
Sub: Gasoline Sub: Electric

Propulsion Motors Engine Combination of motor + engine

Machanism

CO2 Emission None Yes Yes Yes

Fuel Facility Charging station Gas station Gas station, Gas station
Locations chargers

Tax Liability Low High Low Low

Cruising Short Long Long Long

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 Distance

Chapter-3

HYBRID ELECTRIC VEHICLE INDUSTRY

3.1 Electric car manufacturers in India

During April 2012 Indian Government has planned to unveil the roadmap for the
development of the domestic electric and hybrid vehicles (EV) in the country. A discussion
between the various stakeholders including Government, industry and the academia is
expected to take place during 23-24 February. The final contours of the policy will be formed
after this set of discussions. Ministries such as Petroleum, Finance, Road Transport and
Power are involved in developing a broad framework for the sector. Along with these
ministries big auto industry names such as Mr Anand Mahindra (Vice Chairman and
Managing Director, Mahindra & Mahindra) and Mr Vikram Kirloskar (Vice-Chairman,
Toyota Kirloskar) are also involved in this task. Government has also proposed to set up a Rs
740 crore R&D fund for the sector in the 12th five-year plan during 2012-17. The idea is to
reduce the high cost of key imported components such as the battery and electric motor and
develop such capabilities locally.

 Ajanta Group
 Mahindra REVA
 Tata (Indica Vista)
 Hero Electric (Yo Bikes)
 Tara International
 Chevrolet (Beat)

3.2 Manufacturing Facilities

3.2.1 Passenger Vehicles

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 General Motors India Private Limited
 Chevrolet Sales India Private Limited - Halol
 Maruti Suzuki - Gurgaon, Manesar
 Mahindra REVA Electric Vehicles - Bangalore
 Toyota Kirloskar Motor Private Limited - Bidadi
 Ssangyong Motor Company -- Chakan Tata Motors Limited
 Tata Motors - Pimpri Chinchwad, Sanand
 Jaguar Cars and Land Rover - Pune Mercedes-Benz Passenger Cars - Chakan
 Fiat Automobiles - Ranjangaon Pune Volkswagen Group Sales India Private Limited
 Volkswagen-Chakan o Audi AG-Aurangabad
 Skoda Auto-Aurangabad Chinkara Motors - Karlekhind Alibag
 Premier Automobiles Limited - Pimpri Chinchwad
 Honda Siel Cars India - Tapukara BMW India-Chennai
 Ford India Private Limited - Maraimalai Nagar
 Hyundai Motor India Limited - Sriperumbudur
 Mitsubishi - Tiruvallur
 Renault Nissan Automotive India Private Limited
 Nissan Motor India Private Limited - Oragadam o Renault India Private Limited -
Oragadam

3.2.2 Two wheelers

 Hero MotoCorp - Dharuhera, Gurgaon

 India Yamaha Motor - Faridabad
 Honda - Manesar
 Suzuki - Gurgaon
 TVS Motors-Nalagarh, Mysore
 Mahindra & Mahindra - Pithampur
 Bajaj Auto - Waluj Aurangabad, Chakan KTM Sportmotorcycles - Chakan
 Vespa Scooters Baramati Pune
 Kinetic Engineering - Ahmednagar, Pune Royal Enfield Chennai

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 India Yamaha Motor - Greater Noida

3.2.3 Commercial Vehicles

 TAFE Tractors - Parwanoo

 Tata Motors - Jamshedpur
 Volvo Buses India Private Limited - Hoskote
 Force Motors Private Limited - Pithampur
 Eicher Motors - Pithampur
 MAN, Trucks India - Akurdi Pune
 Mercedes-Benz Buses India - Chakan
 Piaggio Vehicles - Baramati Pune Ashok Leyland - Ennore, Hosur

3.3 About Electric Vehicles

During the last few decades, environmental impact of the petroleum-based transportation
infrastructure, along with the peak oil, has led to renewed interest in an electric transportation
infrastructure. Electric vehicles differ from fossil fuel-powered vehicles in that the electricity
they consume can be generated from a wide range of sources, including fossil fuels, nuclear
power, and renewable sources such as tidal power, solar power, and wind power or any
combination of those. An electric vehicle (EV), also referred to as an electric drive vehicle,
uses one or more electric motors or traction motors for propulsion.

Three main types of electric vehicles exist, those that are directly powered from an external
power station, those that are powered by stored electricity originally from an external power
source, and those that are powered by an on-board electrical generator, such as an internal
combustion engine (a hybrid electric vehicle) or a hydrogen fuel cell. Electric vehicles
include electric cars, electric trains, electric Lorries, electric aeroplanes, electric boats,
electric motorcycles and scooters and electric spacecraft.

Proposals exist for electric tanks, diesel submarines operating on battery power are, for the
duration of the battery run, electric submarines, and some of the lighter UAVs are electrically
powered. Electric vehicles first came into existence in the mid-19th century, when electricity
was among the preferred methods for motor vehicle propulsion, providing a level of comfort
and ease of operation that could not be achieved by the gasoline cars of the time.

19
The internal combustion engine (ICE) is the dominant propulsion method for motor vehicles
but electric power has remained commonplace in other vehicle types, such as trains and
smaller vehicles of all types. A hybrid electric vehicle combines a conventional (usually fossil
fuel-powered) powertrain with some form of electric propulsion. Common examples include
hybrid electric cars such as the Toyota Prius. The Chevrolet Volt is an example of a
production Extended Range Plug-In Electric Vehicle. Electric vehicle is a good vehicle and
battery efficiency is good . This vehicle is not polluted environment and not noise pollution.

3.4 Types of Electric Vehicles

There are four types of Electric Vehicles:

1. Battery Electric Vehicle (BEV)

2. Hybrid Electric Vehicle (HEV)

3. Plug-In Hybrid Electric Vehicle (PHEV)

4. Fuel Cell Electric Vehicle (FCEV)

3.4.1 Battery Electric Vehicle (BEV)

A Battery Electric Vehicle, commonly known as a BEV, is an electric vehicle that is entirely
powered by electricity stored in rechargeable batteries. BEVs do not have an internal
combustion engine (ICE). Instead, they rely on an electric motor to propel the vehicle.

They are charged by plugging into an electric power source, such as a charging station or a
standard electrical outlet. BEV produce zero tailpipe emissions and are considered one of the
cleanest forms of transportation when the electricity used for charging comes from renewable
sources.

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 Fig 3.1: - Architectural diagram of battery electric vehicles (BEV)

3.4.2 Hybrid Electric Vehicle (HEV)

A Hybrid Electric Vehicle, or HEV, combines both an internal combustion engine (usually
gasoline) and an electric motor. HEVs use regenerative braking to recover and store energy in
a small battery, which is then used to assist the engine and improve fuel efficiency. Unlike
BEVs, HEVs cannot be charged externally; they generate electricity through the vehicle's
operation (e.g., during braking or deceleration). HEV produce lower emissions and have
better fuel economy compared to traditional gasoline vehicles, but they still rely on fossil
fuels.

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 Fig 3.2: - Architectural diagram of hybrid electric vehicles (HEVs)

3.4.3 Plug-In Hybrid Electric Vehicle (PHEV)

A Plug-In Hybrid Electric Vehicle, also known as a PHEV, is similar to an HEV but has a
larger battery that can be charged externally by plugging into an electric power source.
PHEVs can operate in electric-only mode for a certain range (typically shorter than BEVs)
before switching to the gasoline engine when the battery is depleted. They offer the flexibility
of driving on electricity for short trips and using the gasoline engine for longer journeys,
reducing overall fuel consumption and emissions.

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 Fig 3.3: - Architectural diagram of plug-in hybrid electric vehicles (PHEVs).

3.4.4 Fuel Cell Electric Vehicle (FCEV)

A Fuel Cell Electric Vehicle, or FCEV, uses hydrogen gas as a fuel source to generate
electricity through a chemical reaction in a fuel cell stack. The electricity produced by the
fuel cell powers an electric motor that propels the vehicle. FCEVs emit only water vapor and
heat as byproducts, making them a zero-emission alternative to traditional vehicles. However,
hydrogen infrastructure, such as refuelling stations, is less common compared to electric
charging infrastructure, limiting the widespread adoption of FCEVs.

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 Fig 3.4: - Architectural diagram of fuel-cell electric vehicles (FCEVs).

3.5 Energy efficiency of EVs

Electric vehicle 'tank-to-wheels' efficiency is about a factor of 3 higher than internal

combustion engine vehicles. Energy is not consumed while the vehicle is stationary, unlike
internal combustion engines which consume fuel while idling. However, looking at the well-
to-wheel efficiency of electric vehicles, their total emissions, while still lower, are closer to an
efficient gasoline or diesel in most countries where electricity generation relies on fossil
fuels. It is worth noting that well-to-wheel efficiency of an electric vehicle has far less to do
with the vehicle itself and more to do with the method of electricity production. A particular
electric vehicle would instantly become twice as efficient if electricity production were
switched from fossil fuel to a wind or tidal primary source of energy. Thus when "well-to-
wheels" is cited, one should keep in mind that the discussion is no longer about the vehicle,
but rather about the entire energy supply infrastructure - in the case of fossil fuels this should
also include energy spent on exploration, mining, refining, and distribution.

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3.5.1 Efficiency of EVs

Because of the different methods of charging possible, the emissions produced have been
quantified in different ways. Plug-in all-electric and hybrid vehicles also have different
consumption characteristics.

3.5.2 Range of EVs

Many electric designs have limited range, due to the low energy density of batteries
compared to the fuel of internal combustion engine vehicles. Electric vehicles also often have
long recharge times compared to the relatively fast process of refuelling a tank. This is further
complicated by the current scarcity of public charging stations. "Range anxiety" is a label for
consumer concern about EV range.

3.5.3 Grid capacity

If a large proportion of private vehicles were to convert to grid electricity it would increase
the demand for generation and transmission, and consequent emissions. However, overall
energy consumption and emissions would diminish because of the higher efficiency of
electric vehicles over the entire cycle.

3.5.4 Stabilization of the grid

Since electric vehicles can be plugged into the electric grid when not in use, there is a
potential for battery powered vehicles to even out the demand for electricity by feeding
electricity into the grid from their batteries during peak use periods (such as mid-afternoon air

conditioning use) while doing most of their charging at night, when there is unused
generating capacity. This vehicle-to-grid (V2G) connection has the potential to reduce the
need for new power plants, as long as vehicle owners do not mind their batteries being
drained during the day by the power company prior to needing to use their vehicle for a
return-commute home in the evening. Furthermore, our current electricity infrastructure may
need to cope with increasing shares of variable-output power sources such as windmills and
PV solar panels. This variability could be addressed by adjusting the speed at which EV
batteries are charged, or possibly even discharged. Some concepts see battery exchanges and
battery charging stations, much like gas/petrol stations today. Clearly these will require

25
enormous storage and charging potentials, which could be manipulated to vary the rate of
charging, and to output power during shortage periods, much as diesel generators are used for
short periods to stabilize some national grids.

3.6 Heating of electric vehicles

In cold climates, considerable energy is needed to heat the interior of a vehicle and to defrost
the windows. With internal combustion engines, this heat already exists as waste combustion
heat diverted from the engine cooling circuit. This process offsets the greenhouse gases
external costs. If this is done with battery electric vehicles, the interior heating requires extra

energy from the vehicle’s batteries. Although some heat could be harvested from the motor(s)
and battery, their greater efficiency means there is not as much waste heat available as from a
combustion engine. However, for vehicles which are connected to the grid, battery electric
vehicles can be preheated, or cooled, with little or no need for battery energy, especially for
short trips. Newer designs are focused on using super-insulated cabins which can heat the
vehicle using the body heat of the passengers. This is not enough, however, in colder climates
as a driver delivers only about 100 W of heating power. A reversible AC-system, cooling the
cabin during summer and heating it during winter, seems to be the most practical and
promising way of solving the thermal management of the EV. Ricardo Arboix introduced
(2008) a new concept based on the principle of combining the thermal-management of the
EV-battery with the thermal-management of the cabin using a reversible AC-system. This is
done by adding a third heat-exchanger, thermally connected with the battery-core, to the
traditional heat pump/air conditioning system used in previous EV Models like the GM EV1
and Toyota RAV4 EV. The concept has proven to bring several benefits, such as prolonging
the life-span of the battery as well as improving the performance and overall energy-
efficiency of the EV.

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 Chapter-4

OPERATION OF ELECTRIC VEHICLE

4.1 Electric Vehicle and its Working Principle

Electric vehicles play a critical role in fighting climate change throughout the world by
lowering emissions and decreasing reliance on fossil fuels.

Electric automobiles not only offer zero tailpipe emissions but also a much-reduced cost of
ownership when compared to typical ICE-powered versions. While electric automobiles are
less expensive to acquire than gasoline or diesel vehicles, they are also easier to maintain.
This is because of the fact that electric vehicles have fewer components than conventional
automobiles.

Fig 4.1: - Model of EV Car

A battery pack, power control unit, electric motor, gearbox, and battery charger are the main
components of an electric automobile.

Let’s understand in detail how an electric motor works:

 When you recharge the battery, the battery pack retains electric current. The energy that
has been stored is used to power the electric engine and other accessories/components.

 The supply of electric power to the motor is managed by a controller.

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 Depending on the data generated from the accelerator pedal, the controller controls the
flow of power.

 The electric motor draws energy from the battery and transforms it into mechanical
energy.

 The transmission is responsible for transferring mechanical power from the motor to the
wheels.

 Some EVs generate braking energy through regenerative braking. The energy created
during vehicle braking or deceleration is returned to the battery pack.

4.2 Electric Vehicles Moving System:

EV’s are like an automatic car. They have a forward and reverse mode. When you place the
vehicle in gear and press on the accelerator pedal these things happen:

 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

 When the brakes are pressed or the car is decelerating, the motor becomes an alternator
and produces power, which is sent back to the battery.

4.3 Working of Electric Vehicle

Through the ignition and combustion of a 15:1 air-fuel mix, the ICE engine converts thermal
energy into mechanical energy and emits waste exhaust gases in the process. Improvements
in efficiency and evolving emission standards, ICE technology has not changed much in the
last 100 years. There are hundreds of moving parts with tight tolerances that must work
together to keep the combustion engine running. When the combustion process starts you can
hear and feel the vibrations in the vehicle caused by the mechanical and hydraulic systems.
ICE engines produce power in a limited speed range and use gears to maintain acceleration.
Fuel keeps burning as long as the engine is switched on, even when the car is idling.
Electrical powertrains convert electrical energy (stored in the battery), into mechanical energy

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which turns the motor, rotating the wheels. EVs have 90% fewer moving parts than ICE
vehicles.

4.4 Conversion of Maruti 800 Form Petrol to Electric

Converting a petrol-powered Maruti 800 car to an electric vehicle (EV) involves a detailed
process. Here is a step-by-step process:

Fig 4.2: - Maruti 800 Car (petrol version)

4.4.1 Assessment and Planning

First of all, we started the process by thoroughly assessing the existing petrol-powered Maruti
800 car, including its chassis, suspension, and electrical system. Then we Determine all the
required specifications for the electric powertrain, including motor, battery pack, and
controller etc.

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 Fig. 4.3: - Assessment and Planning

4.4.2 Dissembling of Maruti 800:

 Remove Petrol Engine and Components:

Converting a Maruti 800, or any internal combustion engine (ICE) car, into an electric car
involves a complex process that includes removing various ICE-related components and
installing electric propulsion components. Here is a simplified overview of the major parts
that are typically removed or modified when converting a Maruti 800 into an electric car:

Fig. 4.4: - Remove Petrol Engine and Components

 Internal Combustion Engine (ICE):

The first and most significant step is removing the gasoline engine, including the engine
block, exhaust system, and related components. This is the heart of the ICE car, and it will
no longer be needed.

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 Fig: 4.9: - ICE
 Fuel Tank:
Since an electric car does not use gasoline, the fuel tank can be removed or repurposed for
other uses.

Fig 4.6: - Removed Fuel Tank of Maruti 800

 Transmission:
Some electric conversions retain the existing transmission, while others replace it with an
electric motor and a single-speed transmission or reduction gear.
 Exhaust System:
The exhaust pipes, muffler, and related components are unnecessary for an electric car and
can be removed.
 Radiator and Cooling System:
The radiator, cooling fan, and associated components used to cool the ICE are no longer
required. Electric motors typically have their cooling systems.

31
 Fig 4.7: - Removed Radiator of Maruti 800
 Gasoline Fuel Lines: All fuel lines and related components should be removed as they
serve no purpose in an electric vehicle.
 Engine Control Unit (ECU): The ECU that controls the engine's performance can be
removed as it is not needed for an electric motor.
 Exhaust Emissions Components: Components such as the catalytic converter and
oxygen sensors can be removed since there are no emissions in an electric vehicle.
 Clutch and Related Components: In cases where the existing transmission is retained,
the clutch and clutch-related components may be removed or modified.
 Gas Pedal and Linkages: The gas pedal and its linkages can be replaced with an
accelerator pedal for the electric drive system.
 Ignition System: Components such as the spark plugs, ignition coils, and distributor are
no longer needed in an electric car.
 Exhaust Manifold: The exhaust manifold, which connects the engine to the exhaust
system, can be removed.
 Engine Mounts: The engine mounts may need to be modified or replaced to
accommodate the electric motor.
4.4.3 Component Selection
Electric vehicles consists of an electric motor that is powered by a battery pack. The main
advantage of electric vehicle components is that they emit zero emissions and are eco-
friendly. They also do not consume any fossil fuels, hence use a sustainable form of energy
for powering the car. The main components of electric vehicles are -
4.4.3.1 Traction Battery Pack

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Traction battery pack is also known as Electric vehicle battery (EVB). It powers the electric
motors of an electric vehicle. The battery acts as an electrical storage system. It stores energy
in the form DC current. The range will be higher with increasing kW of the battery. The life
and operation of the battery depends on its design. The lifetime of a traction battery pack is
estimated to be 200,000 miles.

Previously banks of conventional lead-acid car batteries were commonly used for EV
propulsion. Then later the 75 watt-hour/kilogram lithium-ion polymer battery prototypes
came. The newer Li-poly cells provide up to 130 watt-hour/kilogram and last through
thousands of charging cycles.

Fig. 4.8: - Battery Pack

4.4.3.2 DC-DC Converter
The traction battery pack delivers a constant voltage. But different components of electric
vehicle have different requirements. The DC-DC convertor distributes the output power that

33
is coming from the battery to a required level. It also provides the voltage required to charge
the auxiliary battery.

Fig. 4.9: - DC Converter

4.4.3.3 Electric Motor
Electric traction motor is the main components of electric vehicles. The motor converts the
electrical energy into kinetic energy. This energy rotates the wheels. Electric motor is the
main components of electric vehicle that differentiates an electric car from conventional cars.
An important feature of an electric motor is the regenerative braking mechanism. This
mechanism slows down the vehicle by converting its kinetic energy into another form, and
storing it for future use. There are basically two types of motors DC and AC motors.

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 Fig. 4.10: - Electric Traction Motor

4.4.3.3.1 Brushless DC Motor

A brushless DC motor (known as BLDC) is a permanent magnet synchronous electric motor

which is driven by direct current (DC) electricity. The main function of motor is to convert
supplied electric energy current in to mechanical energy. Brushless DC motor (BLDC) have
been much focused for many motor manufacturers.

These are more effective in term of System cost, size, higher in efficiency, excellent
controllability and also power saving than other motor. It has only two basic main parts Rotor
and stator. The rotor is rotating part which carry permanent magnet and stator is stationary
part and containing stator winding. The structure of stator is similar to the induction motor. It
is made up of steel lamination with axially cut for winding.

Previously banks of conventional lead-acid car batteries were commonly used for EV
propulsion. Then later the 75 watt-hour/kilogram lithium-ion polymer battery prototypes
came. The newer Li-poly cells provide up to 130 watt-hour/kilogram and last through
thousands of charging cycles.

Fig. 4.11: -BLDC Motor

4.4.3.4 Electromagnetic Radiation

Electromagnetic radiation from high performance electrical motors has been claimed to be
associated with some human ailments, but such claims are largely unsubstantiated except for

35
extremely high exposures. Electric motors can be shielded within a metallic Faraday cage, but
this reduces efficiency by adding weight to the vehicle, while it is not conclusive that all
electromagnetic radiation can be contained.

4.4.3.5 Controller

An electric vehicle motor controller is a machine that is employed to regulate the torque
generated by the motors of electric vehicles by means of modifying the energy flow from the
power sources to the motor. In most of the electric vehicle, Brushless DC motor is used
which is better than brushed DC motor, permanent magnet DC motor. Brushless DC motor
does not have brush and commutator, the electric vehicle which uses brushless DC motor has
to use motor controller which helps to control various properties of motor to take sufficient
current and voltage applied to motor. When accelerating pedal is press, this linked variable
resistor type controller gives signal to the motor controller to adjust speed as per our needs.
The motor controller has no power when vehicle is at rest position.

Fig. 4.12: - Motor controller

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 Fig. 4.13: - Assembled Controller with Converter

4.4.3.6.Thermal Cooling System:

The thermal management system is responsible for maintaining an operating temperature for
the main components of electric vehicle (EV) such as, electric motor, controller etc. It
functions during charging as well to obtain maximum performance. It uses a combination of
thermoelectric cooling, forced air cooling, and liquid cooling.

37
4.4.3.6 Onboard Charger:

Onboard charger is used to convert the AC supply received from the charge port to DC
supply. The on-board charger is located and installed inside the car. It monitors various
battery characteristics and controls the current flowing inside the battery pack.

4.4.3.7 Power Control Unit:

The power control unit is a crucial component that transforms DC power generated by the
battery back into AC power, which the majority of electric motors need. An inverter, a part
used to power computers or other equipment utilizing a 12-volt plug in the vehicle’s dash, is
utilized to finish this operation. The drivetrain is connected to the accelerator, start button,
and drive mode controller via a power control unit. Additionally, it controls regenerative,
which is how an EV sends energy back to the battery system when slowing.

4.4.4 Assembling Maruti 800 Into Electric Car

4.4.4.1 Battery Installation:

Install the selected batteries in a secure and well-ventilated location. Common locations
include the engine bay or where the fuel tank used to be. Ensure proper cooling and thermal
management for the batteries.
4.4.4.2 Motor Controller Integration:
Connect a motor controller to the electric motor to regulate power delivery. Wire the motor
controller to the vehicle's control systems.

Fig. 4.14: - Assemble Controller in Car

4.4.4.3 Wiring and Electronics:

38
Rewire the vehicle to accommodate the electric motor and batteries. Install safety features
like a Battery Management System (BMS) and fuses.

4.4.4.4 Charging Infrastructure:

Set up an EV charging system, either at your home or a designated charging station.

4.4.4.5 Testing and Calibration:

Conduct thorough testing to ensure all components are functioning correctly. Calibrate the
motor controller and BMS for optimal performance and safety.
4.4.4.6 Safety Considerations:

Converting a car to electric power involves significant electrical and mechanical

modifications, and if not done properly, it can pose safety risks. Here are some important
safety considerations for a petrol to EV conversion:

 Qualified Professionals: Ensure that the conversion is carried out by qualified

professionals who have expertise in EV technology and automotive engineering. DIY
conversions without the necessary knowledge can lead to safety hazards.
 Battery Safety: Properly install and secure the battery pack to prevent it from moving or
shifting during operation. Implement a robust battery management system (BMS) to
monitor and manage individual cells within the battery pack. This helps prevent
overcharging, overheating, and other potential issues. Use high-quality, certified lithium-
ion batteries that meet safety standards.
 Cooling and Thermal Management: Implement an effective thermal management
system to regulate battery pack temperature. Overheating can lead to reduced battery life
and safety concerns. Install cooling systems for the electric motor and controller to prevent
overheating.
 Emergency Disconnect: Include a manual emergency disconnect switch that can quickly
isolate the high-voltage components in case of an emergency or accident.
 Crash Safety: Consider the impact of potential accidents on the battery pack. Install
proper reinforcement and safety measures to prevent damage to the battery in the event of
a collision.

39
 Charging Safety: Ensure the charging infrastructure complies with safety standards and
regulations. Use a charging system that incorporates safety features such as overcurrent
protection and ground fault protection.
 Testing and Inspection: Conduct thorough testing and inspections of the conversion
before putting the vehicle into regular use. Regularly inspect and maintain the electric
components, wiring, and connectors to ensure they are in good condition.
 Regulatory Compliance: Ensure that the converted vehicle complies with local
regulations and safety standards. This may include inspections and certifications from
relevant authorities.
 Vehicle Handling: Be aware that the weight distribution and handling characteristics of
the vehicle may change after the conversion due to the added weight of the batteries.
Ensure that the suspension and brakes are upgraded as needed to maintain safe handling.

4.5 Performance

Performance electric vehicles (EVs) are designed to deliver impressive acceleration, top
speed, handling, and overall driving dynamics. They are often known for their ability to
combine the benefits of electric power with high-performance characteristics.

Fig. 4.15: - Electric Maruti 800 Car

40
Here are some key aspects of a performance EV:

 Acceleration: Performance EVs are known for their rapid acceleration due to the instant
torque delivery of electric motors. They can often achieve 0 to 60 mph (0 to 100 km/h)
times in a matter of seconds, rivaling or even surpassing some high-performance gasoline-
powered cars.
 Top Speed: Performance EVs typically have high top speeds, allowing for thrilling
driving experiences on highways and race tracks. Some models can exceed 150 mph (240
km/h) or more.
 Power Output: These EVs boast high power outputs from their electric motors. This can
range from 300 horsepower in entry-level performance EVs to well over 1,000 horsepower
in hyper cars.
 Handling: Performance EVs often feature advanced suspension systems, precise steering,
and well-tuned chassis to provide exceptional handling and cornering abilities. Many have
a low centre of gravity thanks to their heavy battery packs, which enhances stability and
handling.

 Battery Technology: Performance EVs often use cutting-edge battery technology to

provide high energy density and fast charging capabilities. This allows for extended range
and quick charging stops during long drives.
 Regenerative Braking: Many performance EVs feature regenerative braking systems that
recover energy during braking, improving overall efficiency and reducing brake wear.
 Range: While not the primary focus of performance EVs, many of them offer respectable
driving ranges on a single charge. Modern models can often exceed 300 miles (480 km)
per charge.
 Design and Aerodynamics: Performance EVs often have aerodynamic designs to reduce
drag and improve stability at high speeds. These designs can be both functional and
visually striking.
 Sound: Some performance EVs are equipped with artificial sound systems to mimic the
sound of a traditional internal combustion engine, providing a more familiar driving
experience to enthusiasts.
 Technology: Performance EVs are equipped with advanced technology, including large
touchscreen displays, driver assistance features, and over-the-air software updates.

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 Table 4.1: Specifications of Electric Maruti 800 Car after Conversion

S. NO. Description values

1 Motor Capacity 1.5 KW

2 Motor Type BLDC

3 Battery Incharge Capacity 6.2 kwh

4 Range 120 km

5 Top Speed 80 kmph

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 CONCLUSION

The training at UVIK Automobile was very useful. This training experience of converting a
conventional Maruti 800 car into an electric Maruti 800 car has been both educational and
transformative. This endeavour has provided valuable insights into the world of electric
vehicles and sustainable transportation. Throughout the course of this training, we have not
only acquired technical skills but also gained a deep appreciation for the potential of electric
vehicles to revolutionize the automotive industry and contribute to a greener future.

Our journey involved extensive research, planning, and hands-on work, from selecting the
appropriate components and batteries to designing the electrical system and integrating it
seamlessly into the car's chassis. We encountered challenges and setbacks, but they only
served to enhance our problem-solving abilities and teamwork.

The significance of electric vehicles in reducing carbon emissions, mitigating climate change,
and promoting energy efficiency cannot be understated. As we move toward a future where
sustainable transportation is paramount, our experience in converting a conventional car to an
electric one underscores the importance of innovation, adaptation, and collaboration in
achieving this transition.

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