An electric vehicle conversion is the modification of a conventional internal combustion engine vehicle (ICEV) to electric propulsion, creating an all-electric or plug-in hybrid electric vehicle.
Elements of a conversion
- Almost any vehicle can be converted to electric. Many people prefer to pick a vehicle that is light and aerodynamic in order to maximize distance traveled per battery charge. There must also be adequate room and load capacity for batteries.
- The battery pack, which provides a source of electrical power. The most commonly available and affordable batteries are lead acid flooded type. Next are the AGM (Absorption Glass Mat) sealed maintenance free batteries, a little more powerful and expensive. Then there are the more exotic batteries like Ni-MH and Li-ion; more difficult to find but light and longer lasting, maintenance free, and much more expensive. The new lithium batteries are showing some promise for EVs in the near future.
- The charger which restores energy to the batteries (which may be mounted within the vehicle or at a special charging station at some fixed location)
- The power controller, which regulates the flow of energy between the battery and the electric motor(s), controlled by an electronic throttle.
- One or more electric motors and their mechanical attachment to the driveline
- Power conductors connecting the battery, controller, and motor(s)
- Accessory equipment to power auxiliary equipment such as power brakes and heating system
- Control circuitry and equipment to allow control and interlocking of the various components
- Instrumentation specific to the operation and maintenance of the conversion
Solar power
Main article: Solar vehicleSolar cells could be used to power a vehicle converted to electric. However, currently the relatively small power generated by solar cells means that the other components in the system must be special to compensate for this. For example, the body of even a small conventional car converted to electric is still rather too heavy to be able to be matched with an electric system that is solely or primarily charged by solar power. Thus, it is usually more practical to create a solar-powered electric vehicle from scratch or specially made parts.
Conversion process
Most conversions in North America are performed by hobbyists who typically will convert a well used vehicle with a non-functioning engine, since such defective vehicles can be quite inexpensive to purchase. Other hobbyists with larger budgets may prefer to convert a later model vehicle, or a vehicle of a particular type. In some cases the vehicle itself may be built by the converter, or assembled from a kit car.
A two-stage vehicle is a vehicle that has been built by two separate manufacturers. The result is a standard, complete vehicle. In this process, vehicles may be converted by a manufacturer (as was done by Ford Motor Company to create the Ford Ranger EV). Alternatively, in a process known as "third-party (power)trainization", an independent converter will purchase new vehicle gliders (vehicles without a motor or related equipment) and then perform the conversion, to offer a two-stage vehicle.
In some countries, the user can choose to buy a converted vehicle of any model in the automaker dealerships only paying the cost of the batteries and motor, with no installation costs (it is called pre-conversion or previous conversion).
Industry
The electric vehicle conversion industry has grown to include conversion car garages , aftermarket kits and vehicle components .
Vehicle types
Electric bicycle
An electric bicycle is a conventional bicycle that has been fitted with an electric motor. Converting an existing bicycle by retrofitting it with a "conversion kit" or "E-BikeKit" is the simplest and least expensive electric vehicle conversion option. Most often electric bicycles or "e-bikes" are powered by rechargeable batteries however some experimental electric bicycles run directly on or recharge their batteries via solar panels, fuel cells, gas generators or other alternative energy sources. Some experimenters have even used super capacitors to store energy. Using an on-board generator may impact the legal jurisdictional definition of an electric bicycle. A few types of electric bicycles are able to re-capture a small amount of energy from braking and can re-charge the batteries while braking or traveling down hills (regenerative braking). With the advent of newer technology further features can be expected.
Some electric bikes have features where the motor can move the bicycle by itself (immediate start) if the rider chooses not to pedal, while others require the rider to pedal at all times (pedal assist). This latter type may in some jurisdictions allow the vehicle to be used on bicycle trails that otherwise prohibit motorized vehicles of any kind (See motorized bicycle). Electric bikes converted with a E-BikeKit conversion system fall under the rules and regulations of the Federal Electric Bicycle Law.
Many battery technologies are available for powering electric bikes. The most common and least expensive battery technology is sealed lead acid but LiFePO4 is fast becoming the battery of choice for the e-bike.
Converting one's bike to electric with a conversion kit is an easy and affordable solution for most people interested in learning more about electric vehicle conversion. E-Bikes are the cleanest, most affordable and most energy efficient form of transportation on the planet.
Electric motorcycle and Scooters
Low-speed Scooters are not typically suitable for on-the-road use. These may be configured for either standing or sitting use. Some local laws apply bicycle laws to scooters, such as helmet and pedestrian right-of-way considerations.
Motorcycle conversions are a specialty niche which can offer an opportunity to build a relatively low-cost electric vehicle. Most of these use a two-wheel configuration, although the two types of three-wheel vehicle (and sometimes four-wheel vehicles) are classified as motorcycles in many jurisdictions if their weight is sufficiently low (typically around 500 kg/1000 pounds maximum). If a tricycle layout is employed, greater handling stability is obtained with the single wheel at the back, with normal automotive front wheel steering, as compared with placing the single wheel in the front.
Economy coupe
Owing to its light weight and efficiency, a light vehicle can make an excellent choice, particularly if care is taken in component selection and placement. It is possible to obtain conversion kits for some popular light vehicles, most notably the rear motor, rear drive Volkswagen Beetle, its Type 3 evolution, and its successor, the front motor/drive VW Rabbit.
By converting a light vehicle it is possible to use a smaller motor, which both weighs and costs less than a larger motor. A lighter overall vehicle weight will reduce power consumption in start-and-stop traffic and increase range in many practical driving conditions.
Compact sedan or coupe
A compact sedan may be a better choice than a subcompact owing to better load capacity and more room for battery placement. Some commercial EV Conversions use vehicles in this size range. One example is a 1992 Honda Civic. In this conversion, the back seat was retained, and there is still enough room to sink nine flooded lead-acid batteries low in the trunk where the spare tire was located, as well as another nine batteries under the hood. Another example is a 1987 Mitsubishi Tredia where the rear batteries have been raised above the trunk floorspace, sealed, and externally vented. With suspension modifications, increasing shock length & spring rating, the car must still be below GVWR, even with the driver and passengers. Exceeding the total design weight of the vehicle would be illegal in some states, and might result in cancellation by an insurance company.
There is an effort by several engineers in California to make the Toyota Prius a "Plug-In Hybrid Electric Vehicle," or PHEV, whereby the first 40 miles are driven by all-electric power, then the gas engine comes on to re-charge the batteries, only if the commute is further than 40 mi. If it's less, one can just plug it into the utility grid to re-charge the batteries. The process is done by removing the nickel-metal hydride batteries, and installing different batteries, and a different battery management system.
Since 30 April 2009, the Electric Car Corporation have been selling the Citroën C1 ev'ie, an all-electric conversion from the Citroën C1.
Full-size sedan
Full-size sedans and minivans are generally considered to be poor candidates for EV conversion. As the suspension and tires are already operating close to the maximum permissible, it may be necessary to make substantial modifications in these areas. It may be easier to obtain upgraded suspension components for some smaller vehicles, if these are also typically used for sports racing (particularly autocross). Starting with a heavy vehicle and adding batteries will result in poor performance in acceleration, handling, braking, and economy of operation.
One of possibilities is using the body of Audi's D2 platform A8 (1994-2003) Audi A8 or sports sedan S8 (1998-2003 or o
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