Saudi Journal of Engineering and Technology

Abbreviated Key Title: Saudi J Eng Technol

ISSN 2415-6272 (Print) | ISSN 2415-6264 (Online)
Scholars Middle East Publishers, Dubai, United Arab Emirates
Journal homepage: https://saudijournals.com

Original Research Article

Electric Car Conversion

C. O. Oloye1, S. A. Olanlokun2, O. S. Emene2, E. I. Bello2, J. F. Eiche3*, K. A. Imoukhuede1
1Department of Mechanical Engineering, Rufus Giwa Polytechnic, Owo, Ondo State, Nigeria
2Department of Mechanical Engineering, Federal University of Technology Akure, Ondo State, Nigeria
3Department of Mechanical Engineering, Olusegun Agagu University of Science and Technology, Okitipupa, Ondo State, Nigeria

DOI: 10.36348/sjet.2024.v09i02.001 | Received: 06.12.2023 | Accepted: 10.01.2024 | Published: 01.02.2024

*Corresponding author: J. F. Eiche
Department of Mechanical Engineering, Olusegun Agagu University of Science and Technology, Okitipupa, Ondo State, Nigeria

Abstract
One of the directions for making cleaner and more economic vehicles is to adopt electric vehicle concept. Therefore, an
internal combustion powered engine Nissan Micra Vehicle was converted into battery powered electric vehicle. The power
train of the car was redesigned to use DC electric motor in replacement of the existing internal combustion engine and to
give the gear ratios possibility of a normal car. The power rating of the motor was determined by considering the rolling,
gradient and aerodynamic resistances which gave a total tractive effort of 12190.84 N. The designed power rating was then
determined to be 8 kW and this value was used to select the number of batteries that gave the required current to reach an
adequate range of operation. To balance the weight of the car, the battery rack was located behind the center of gravity to
give the developed vehicle a neutral steer characteristic. After installation of electric motor, inverter and the batteries, then
the batteries were connected in series and parallel to the inverter with cable wire via variable frequency drive to ac motor
and potentiometer. The vehicle was then evaluated and the voltage produced was able to move the vehicle at 6.24 m/s and
the maximum frequency obtained was fifty megahertz (50 MHz).
Keywords: Electric vehicle, batteries, inverter, gear ratio, rolling resistance, gradient resistance, aerodynamic resistance.
Copyright © 2024 The Author(s): This is an open-access article distributed under the terms of the Creative Commons Attribution 4.0 International
License (CC BY-NC 4.0) which permits unrestricted use, distribution, and reproduction in any medium for non-commercial use provided the original
author and source are credited.

1. INTRODUCTION fossil fuels, nuclear power, and renewable sources such

One of the major challenges in the global as tidal power, solar power and wind power or any
society today is how to mitigate the negative impacts of combination of those (Hawkins et al., 2013). EV also
road transportation on the environment due to toxic and refers to a vehicle powered by an electric motor instead
green-house-gas emissions (IPCC, 2020). The of internal combustion engine (ICE), and the motor is run
automobile industry is the largest producer of using the energy stored in the batteries and the batteries
greenhouse gases in addition to other environmental have to be charged frequently by plugging into the main
pollutants accounting for as much as 41% of global (240 V) supply which could be within or outside the
warming sources (Nordelöf et al., 2014). As a vehicle (Massimo, 2011). The batteries used in electric
consequence, these environmental pollutants from cars vary in design, and include the lead-acid type
vehicles are legally regulated on national and sometimes familiar to all conventional car owners (albeit, much
regional levels. In order to comply with these larger than in a normal car), lithium ion (similar to those
regulations, vehicle manufacturers are now investing in used in laptops and mobile phones, but once again much
various fuel saving technologies and this has led to larger), molten salt, zinc-air, and various nickel-based
increased interest in vehicle electrification, foremost designs (Massimo, 2011). EVs are known as zero
hybrid electric vehicles (HEVs) which can reduce fuel emissions vehicles (ZEVs) while neglecting the battery
consumption compared to conventional vehicles, and charging source and are more environment friendly than
also electric vehicles (Möller et al., 2019). gasoline powered vehicles. As EVs have fewer moving
parts, maintenance is also minimal; with no engine, there
Electric vehicles (EV) differ from fossil fuel- are no oil changes, tune-ups, or timing and there is no
powered vehicles in that the electricity they consume can harmful exhaust emission (Ruan, 2016).
be generated from a wide range of sources, including

Citation: C. O. Oloye, S. A. Olanlokun, O. S. Emene, E. I. Bello, J. F. Eiche, K. A. Imoukhuede (2024). Electric Car 27
Conversion. Saudi J Eng Technol, 9(2): 27-33.
 C. O. Oloye et al; Saudi J Eng Technol, Feb, 2024; 9(2): 27-33
Recently, several researches have been Cross sectional area of the Car is 2.5532 𝑚2
conducted on Electric vehicle, for example, Jardel and Front track is 1359 mm
Jair (2019) converted an ICE-powered Mercedes-Benz Rear track is 3121 mm
Class A 190 into an EV. The results of several tests Ground clearance is 150 mm
indicated that the conversion is feasible, as the car Weight specification unload is 835 kg
reached an average travelling cost of 0.16 R$/km, Gross weight limit is 1340 kg
assuming a price for the energy of 0.63 R$/kWh. Design weight of the vehicle is 2000 kg
Moreover, this cost could be as low as zero if solar Top speed is 154 km/h
radiation is utilized to generate electricity through Weight of the battery is 84 kg
photovoltaic panels, which is an even more Tyres size is 155/70R13
environmentally sustainable solution. Fabian (2021) Aerodynamics drag coefficient (Cd) is 0.33
investigated ICE to EV retrofitting, a potential solution Acceleration of the car is 3.568 m/s2
to improve the transition to widespread adoption of EVs,
using the case of Germany. The research developed a 2.3 Deign Analysis
business model that highlighted how a company can set The equations used for the design of electric
up and integrate ICE to EV conversion into existing motor conversion are as shown in equations 1 to 17
market structures. Xiaoli et al., (2020) provided a respectively as extracted from the studies of Gari (2012),
comprehensive review of the technical development of Eydgahi (2015), Ali (2011), Mark and Sanath (2017),
EVs and emerging technologies for their future and Buddhi (2016)
application. Key technologies regarding batteries,
charging technology, electric motors and control, and The following equations were used in the design:
charging infrastructure of EVs were summarized. The 𝐹𝑟𝑜𝑙𝑙𝑖𝑛𝑔 = 𝐶𝑟 𝑀 𝑔 ………………………….….. (1)
paper also highlighted the technical challenges and 𝐹𝑔𝑟𝑎𝑑𝑖𝑒𝑛𝑡 = 𝑀 𝑔 sin 𝛼 …………………….…... (2)
emerging technologies for the improvement of 𝟏
𝐹𝑎 = 𝟐 𝜌𝑎 𝐶𝑑 𝐴𝑓 (𝑣𝑐𝑎𝑟 )2 ……………………. (3)
efficiency, reliability, and safety of EVs in the coming
stages as another contribution. Holms and Rony (2010) 𝐹i = 𝑎 × 𝑊𝑒𝑖𝑔ℎ𝑡𝑐𝑎𝑟 ……………………...….. (4)
explained in their report the working of electric vehicle 𝐹𝑡𝑜𝑡𝑎𝑙 = 𝐹𝑟𝑜𝑙𝑙𝑖𝑛𝑔 +𝐹𝑔𝑟𝑎𝑑𝑖𝑒𝑛𝑡 + 𝐹𝑎 +𝐹I …...… (5)
and compared it with the conventional internal 𝐹start = 𝐹I + 𝐹rolling ………………………..….. (6)
combustion engine and hybrid electric vehicle. The 𝑃𝑡 = (𝐹𝑡𝑜𝑡𝑎𝑙 𝑋 𝑣)𝑛𝑔 ………………………..….. (7)
report provided the details of advantages and cap = N V A ………………………………..… (8)
disadvantages of Electric Vehicles along with the future Cap
R = 𝐹 ………………………………………. (9)
views of technology. top
R
𝑇= ……………………………….…… (10)
𝑣𝑐𝑎𝑟
In Nigeria, there is a long-time tendency within
𝐴𝑏 = 2(𝑙𝑏 𝑤𝑏 + 𝑙𝑏 ℎ𝑏 + ℎ𝑏 𝑤𝑏 ) + 𝐴𝑙 ….... (11)
automotive industry to build vehicles with as low CO2 1
emission as possible. Large vehicle manufacturers make 𝑓 = 𝑇 ………………………………….……. (12)
enormous investments in the development of hybrid 𝑃 = 𝑉𝐴𝑐𝑜𝑠𝜃 ………………………………… (13)
drive vehicles, fuel cell powered vehicles and electric 𝑎𝑐𝑡𝑢𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑒𝑠𝑖𝑔𝑛
𝑀𝑂𝑆𝐹𝐸𝑇𝑠 = 𝑝𝑜𝑤𝑒𝑟 𝑟𝑎𝑡𝑖𝑛𝑔 𝑜𝑓 𝑡ℎ𝑒 𝑀𝑂𝑆𝐹𝐸𝑇𝑠 ..….. (14)
vehicles. This paper therefore describes a modification 𝑜𝑢𝑡𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟
procedure for a Nissan Micra vehicle and a comparative 𝑑𝑟𝑎𝑖𝑛 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 = 𝑏𝑎𝑡𝑡𝑒𝑟𝑦 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 ………..…... (15)
calculation of tractive and dynamic characteristics. The 𝑜𝑢𝑡𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟
𝑙𝑜𝑎𝑑 𝑜𝑢𝑡𝑝𝑢𝑡 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 = 𝑜𝑢𝑡𝑝𝑢𝑡 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 …….. (16)
importance of analyses is emphasized from the aspect of
optimising vehicle parameters when converting ICE 𝐴𝑖 = 2(𝑙𝑖 𝑤𝑖 + 𝑙𝑖 ℎ𝑖 + ℎ𝑖 𝑤𝑖 ) ……………... (17)
powered vehicle into an electric vehicle.
where: 𝐶𝑟 is coefficient of rolling resistance, g
2. MATERIALS AND METHODS is acceleration due to gravity (m/ s2), 𝛼 is road gradient
2.1 Materials (rad), a is acceleration of the car (m/s2), 𝐶𝑑 is
A Micra Nissan car was used to give light aerodynamic drag coefficient, 𝐹𝑎 is aerodynamic drag
weight and more rooms for batteries; lithium ion (N), 𝜌𝑎 is air density (kg/m3 ), 𝐴𝑏 is area of the battery
batteries were used to provide high energy storage compartment (m2 ), 𝐴𝑖 is area of inverter compartment
potential for the car; a 60 kW dc electric motor was (m2 ), R is battery range (m), Cap is battery pack capacity
selected to provide enough power and fed through an (kW.h), 𝑤𝑏 is breadth of the battery box (m), 𝑤𝑖 is
inverter. The current flow to the motor was varied using breadth of the inverter compartment (m), C is
a potentiometer and frequency variable drive system. capacitance ( 𝜇𝐹 ), 𝑀 is designed weight (kg), 𝑛𝑔 is
drivetrain efficiency (%), 𝐴𝑓 is effective cross sectional
2.2. Design Parameters area (𝑚2 ), 𝐹𝑔 is gradient resistance (N), ℎ𝑏 is height of
The design parameters include: the battery box (m), ℎ𝑖 is height of the inverter
Overall length of the car 𝑙𝑐 is 3719 mm compartment (m), 𝐹I is internal resistance force (N), 𝐿𝑏
Overall width of the car 𝑤𝑐 is 1659 mm is length of the battery box (m), 𝐿𝑖 is length of the
Overall height of the car ℎ𝑐 is 1539 mm inverter compartment (m), N is number of battery, 𝑓 is

© 2024 | Published by Scholars Middle East Publishers, Dubai, United Arab Emirates 28
 C. O. Oloye et al; Saudi J Eng Technol, Feb, 2024; 9(2): 27-33
oscillating frequency (Hz), ℎ𝑐 is overall height of the car frequency drive is a device that helps in converting the
(N), 𝑙𝑐 is overall Length of the car (N), 𝑊𝑐 is overall fixed voltage and frequency of the input power provided
width of the car (N), 𝑃𝑡 is power (kW), 𝑃𝑓 is power to the motor, into variable voltage and frequency, and
factor, 𝐹𝑟 is rolling resistance (N), T is time (s), 𝐹s is total this conversion regulates the functioning of the electric
force at starting (N), 𝐹t is total force at top (N), 𝐹𝑝 is total motor used. 500 W load three-phase variable frequency
tractive power (N), 𝑣𝑐 is vehicle speed (m/s), V is voltage drive was selected for the developed vehicle as shown in
(v) Figure 2.

2.4 Selection of Power Train, Variable Frequency 2.5 Conversion Process

Drive (VFD) and Batteries The internal combustion engine (ICE) parts and
The raw power calculation helps to select equipment were removed from the vehicle. These
appropriate electric motor and the number of batteries include: engine and its auxiliary units, engine electric
required. The selection was also made in such a way as wiring, exhaust system, fuel tank and supply system. In
to result in the lowest possible difference in the weight order to place the batteries and change the vehicle
of uninstalled and newly installed elements, while category, the rear bench, the back seats with its
retaining (as much as possible) the original weight accompanying equipment were also removed. The
distribution between the axles. This could not be done electric motor (EM) was then mounted into the vehicle
entirely, due to the fact that the weight of the batteries is and then connected to the gearbox, with mounting
substantially higher than the weight of the full fuel tank. bracket built to ensure that suspension points of installed
Lithium ion batteries were chosen for storing the energy electric motor correspond to the suspension points of
needed because it does not emit fluids or gases during ICE. The accelerator pedal was hooked to a
normal operation, high energy density, good potentiometer that provides the frequency variable drive
performance at high temperature, recyclable and low with the signal that indicates the amount of power to be
memory effect. 8 kVA electric motor with frequency delivered. The installation of electric vehicle and
regulation is chosen to propel the vehicle. The variable potentiometer are shown in Plate 1.

Plate 1: Installation of EM and potentiometer

At the rear part of the vehicle, two sheet steel electric motor and looped with control unit and variable
boxes were fitted to the vehicle boot to accommodate frequencies drives. An inverter was also installed at the
batteries. The cells were placed in two serially / parallel back of the batteries to convert the DC power from the
connected groups, with the output voltage of 4 x 12 V as battery to AC power used in the electric vehicle. The
shown in Plate 2. The batteries were connected to the connections are shown in Plates 3.

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 C. O. Oloye et al; Saudi J Eng Technol, Feb, 2024; 9(2): 27-33

Plate 2: Installation and connection of batteries

Plate 3: Installation of inverter

The petrol filling point was modified to battery voltage respectively. The circuit diagrams, the
accommodate the charging point. A battery charger was power train, the exploded and the wireframe views of the
added so that the batteries could be recharged from any developed EV are shown in Figures 1,2,3,4 and 5
110-volt or 220-volt wall outlet. The gas gauge was respectively.
replaced with voltmeter for the reading of current and

Figure 1: Developed control circuit of the EV

© 2024 | Published by Scholars Middle East Publishers, Dubai, United Arab Emirates 30
 C. O. Oloye et al; Saudi J Eng Technol, Feb, 2024; 9(2): 27-33

Figure 2: Circuit diagram of the developed EV

Figure 3: Power train of the developed EV

© 2024 | Published by Scholars Middle East Publishers, Dubai, United Arab Emirates 31
 C. O. Oloye et al; Saudi J Eng Technol, Feb, 2024; 9(2): 27-33

Figure 4: Exploded view of the developed electric car

Figure 5: The wireframe of the converted car

3. PERFORMANCE EVALUATION to give the gear ratios possibility of a normal car. After
A Nissan Micra car was selected for conversion installation of the electric motor, variable frequency
taking into consideration its light weight and compact drive, batteries and inverter with its driver board
shape. The existing internal combustion engine was configured with fast arithmetic function and floating
removed and AC electric motor attached to the gearbox point operator to process the control using proteus design

© 2024 | Published by Scholars Middle East Publishers, Dubai, United Arab Emirates 32
 C. O. Oloye et al; Saudi J Eng Technol, Feb, 2024; 9(2): 27-33
suite, the vehicle was then tested and the voltage • Hawkins, T. R., Singh, B., Majeau-Bettez, G., &
produced was able to turn the AC motor and move the Strømman, A. H. (2013). Comparative
car. The transmission worked perfectly and the revised Environmental Life Cycle Assessment of
gear was successfully engaged. The control system also Conventional and Electric Vehicles: LCA of
works perfectly in supplying the correct voltage to the Conventional and Electric Vehicles. Journal of
AC motor. During road testing of the developed EV, Industrial Ecology, 17(1), 53–64.
acceleration time of 0 to 60 mph was achieved in 30 • Holms, A., & Rony, A. (2010): Report on
seconds at speed of 6.24 m/s and the maximum Advantages and disadvantages of Electric Vehicles.
frequency recorded was 50 megahertz (50 MHZ). University of California Santa Barbara College of
Engineering.
4. CONCLUSION • IPCC. (2020). Transport — IPCC. [Online]. 2020.
A Nissan Micra vehicle was modified and Available from: https://www.ipcc.ch/ report/
converted to battery powered electric vehicle by ar5/wg3/transport/.
removing the existing internal combustion engine and • Jardel, E. S., & Jair, U. J. (2019): Converting a
installing the AC electric motor. The power rating of the Conventional Vehicle into an Electric Vehicle (EV).
motor was determined by considering the rolling, Brazilian Archives of Biology and Technology.
gradient and aerodynamic resistances. The power rating Vol.62 no.spe: e19190007, 2019
and range of car per charge obtained were used to www.scielo.br/babt
determine the number of batteries that produced the • Mark, B., & Sanath, A. (2017): The Design and
required current. The electric vehicle developed was Construction of a Battery Electric Vehicle
tested and the voltage produced was able to move the car. Propulsion System-High Performance Electric Kart
Acceleration time of 0 to 60 mph was achieved in 30 Application. International Conference on
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