PLUG IN HYBRID ELECTRIC VEHICLE CONVERSION KIT FOR SUZUKI MEHRAN

Mankind is setting goals to battle climate change. The automobile industry is also determined to do so because one of the major causes of climate is carbon emissions from Internal Combustion Engine automobiles. Mankind has shifted its consideration to Electric Vehicles, Hybrid Electric Vehicles, and

Project Title

PLUG IN HYBRID ELECTRIC VEHICLE CONVERSION KIT FOR SUZUKI MEHRAN

Project Area of Specialization

Mechatronics Engineering

Project Summary

Mankind is setting goals to battle climate change. The automobile industry is also determined to do so because one of the major causes of climate is carbon emissions from Internal Combustion Engine automobiles. Mankind has shifted its consideration to Electric Vehicles, Hybrid Electric Vehicles, and Plug-in Electric Vehicles which have many advantages over typical Internal Combustion Engine automobiles. They are greener, quieter, efficient, and more advanced than Internal Combustion Engine automobiles ever were.
In this document, the design of Plug-in Electric Vehicles is discussed. There will be a conversion from Internal Combustion Engine automobile to a daily usage Plug-in Electric vehicle in which Internal Combustion Engine and electric motors will be connected in parallel. It will be powered by both Internal Combustion Engine and motors but not simultaneously. Every component has been selected after multiple calculations and considering possible errors and making it financially affordable for people of developing and underdeveloped countries.
To run two Brushless DC motors, the battery pack will be designed, and it will be charged by an EVSE level two charger and On-Board Charger will also help in efficient charging and help in the increasing lifespan of the battery pack. A Battery Management System will take care of the battery state of charge and will give the user caution when the State of Charge drops below certain levels to either switch to Internal Combustion Engine mode or plug the charger in. To run the motors efficiently, Electronic Speed Controller will be designed and integrated with other systems. It will control the current for motors to get desired speed and torque. Users will interact with the whole system through the HMI display which will display battery and charging statuses, speed, etc.

Project Objectives

1. Integration of Mechanical, Electrical, and Control Systems in the conversion kit
2. Design modification of rear axle.
3. Designing Motor controllers with FOC to control BLDC Hub motors.
4. Designing a custom battery pack/traction pack with BMS to optimize the charge and discharge of LiPO4 batteries.
5. Designing a Level Two Charger.
6. To achieve a minimum speed of 45 km/h on electric Mode.
7. To achieve a minimum distance range of 50 km on Electric Mode.

Project Implementation Method

Our project is about researching, designing, and fabricating PHEV. A PHEV is a vehicle that has both ICE and electric motor to accelerate it and it has a battery pack that is charged by plugging in a grid supply. There are two types of PHEVs: series and parallel. In series PHEV, ICE only charges the battery not contributing to the acceleration of the vehicle but in parallel PHEV both ICE and electric motors contribute to the acceleration of the vehicle, and they don’t do this at the same time.
The PHEV that we will be designing, and fabricating is parallel. It will have two BLDC hub motors installed at either end of the rear axle. Each BLDC is 5000W.To regulate their speed and torque motor controllers are used which are called ESC. They do this by controlling the voltage and current of motors. To run these motors, a battery pack of 250Ah is designed and fabricated. A level two charger will be designed to charge this battery pack. A BMS will also be used to help in running the motors and battery. Further, these and some other components are mentioned and explained below:

Benefits of the Project

1. Ecosystem Friendly: Probably the greatest benefit of a hybrid electric vehicle over a fuel-powered vehicle is that it runs cleaner and has better gas mileage, which makes it harmless to the ecosystem. A hybrid vehicle run on a gas motor and electric engine that cuts fuel utilization and preserves energy.
2. Financial Benefits: A Hybrid vehicle is a lot cleaner and requires less fuel to run, and that implies fewer emanations and less reliance on petroleum derivatives. Lower yearly expense bills and exclusion from clog charges come as less measure of cash spent on the fuel.

Technical Details of Final Deliverable

The final deliverables will be a conversion kit for SUZUKI MEHRAN which will be consisting a battery management system, a Level 2 charger, an electronic speed controller, an HMI display, and 2 hub motors. 

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Transportation

Other Industries

Energy , Others

Core Technology

Clean Tech

Other Technologies

Others

Sustainable Development Goals

Good Health and Well-Being for People, Affordable and Clean Energy, Decent Work and Economic Growth, Responsible Consumption and Production, Climate Action

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com