Convertion of an internal combustion vehicle

to an electric vehicle
Under the supervision of

Dr. Mihir Sarangi

ASSOCIATE PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGY KHARAGPUR

Yash Bhardwaj
13ME33042
Problem Statement
The aim of this study is to do a conversion an internal
combustion vehicle to an electric vehicle using BLDC
6KW motor and Kelly controller(KLS7245HC) to create
a electric vehicle which can be used repeatedly by users
with high efficiency, controllability, durability and low
electric noise generation.
Introduction
 In automobile engineering, electric vehicle conversion is the
replacement of a car's combustion engine and connected components
with an electric motor and batteries, to create an all-electric vehicle.
 Although electric vehicles offer a cost-effective and more
environmental-friendly way to travel, their initial cost can drive
potential buyers away. Electric cars utilize large battery packs for the
energy they use that cost well over tens of thousands dollars for
marketed electric vehicles such as the Tesla Roadster.
 Obviously, everyone is looking for ways to make electric vehicles less
costly. One way of doing this is to consider converting an internal
combustion engine (ICE) vehicle into a new electric one.
 Electric vehicles consist of batteries for energy, an electric motor for power, a
controller to control the flow of energy to the motor, and a potentiometer to
allow accelerator pedal to provide input to the controller.
 The vehicle’s gasoline engine, exhaust system, gas tank, and clutch
assembly will no longer be needed. The manual transmission is bolted
to the electric motor and then secured to the vehicle’s frame.
 6 battery-packs are installed in the vehicle containing 12-volt deep-
cycle batteries that are wired in series.
 In this paper, we describe a method to effectively convert an ICE vehicle
to an electrical one with a small budget that results in a vehicle
comparable to marketable cars.
 The electric components used in this electric conversion process are:
1.) Brusless DC Motor
2.) Kelly controller (KLS7245HC)
3.) 6 12-volt Exide battery-packs
 The main objective of this project was to create a process that can be
repeated and used by others. This project is very cost- effective and
complete conversion including the initial batteries costs less than a
quarter of the cost of existing kits.
Brushless DC Motor
 A brushless DC electric motor (BLDC motor or BL motor), also
known as electronically commutated motor (ECM or EC motor)
and synchronous DC motors, are synchronous motors powered
by DC electricity via an inverter or switching power
supply which produces an AC electric current to drive each
phase of the motor via a closed loop controller.
 The controller provides pulses of current to the
motor windings that control the speed and torque of the motor.
 With the brushed motor, rotation is achieved by controlling the
magnetic fields generated by the coils on the rotor, while the
magnetic field generated by the stationary magnets remains
fixed
 With a BLDC motor, it is the permanent magnet that rotates;
rotation is achieved by changing the direction of the magnetic
fields generated by the surrounding stationary coils. To control
the rotation, you adjust the magnitude and direction of the
current into these coils.
Advantages of BLDC Motor
 Efficiency: These motors can control continuously at maximum rotational
force (torque). Brushed motors, in contrast, reach maximum torque at only
certain points in the rotation. For a brushed motor to deliver the same torque
as a brushless model, it would need to use larger magnets. This is why even
small BLDC motors can deliver considerable power.
 Controllability: BLDC motors can be controlled, using feedback
mechanisms, to delivery precisely the desired torque and rotation speed.
Precision control in turn reduces energy consumption and heat generation,
and—in cases where motors are battery powered—lengthens the battery life.
 High durability and Low electric noise generation: Thanks to the lack of
brushes. With brushed motors, the brushes and commutator wear down as a
result of continuous moving contact, and also produce sparks where contact
is made. Electrical noise, in particular, is the result of the strong sparks that
tend to occur at the areas where the brushes pass over the gaps in the
commutator. This is why BLDC motors are often considered preferable in
applications where it is important to avoid electrical noise.
Specifiacation of BLDC Motor
Kelly Controller

KLS controller is supposed to reduce the noise of BLDC motor, especially

for hub motor.
The BLDC motor must be based on 3 hall sensors.
We can program the KLS controller on PC software.
We also need a Z-TEK USB to RS232 cable for programming the controller
Kelly Controller- General Function
Extended fault detection and protection. Customers can read the error code in PC software.
Monitoring battery voltage.
 Built-in current loop and over current protection.
Configurable motor temperature protection range.
 Maximum reverse speed and forward speed can be configured between 20% and 100%
respectively and separately.
Provision of a +5 volt and +12 volt output to supply various kinds of hall sensors.
5 switch inputs which are activated by connection to 12V. Default to throttle switch, brake
switch, reversing switch, forward switch and Boost switch.
 2 analog 0-5V inputs that default to throttle input, and motor temperature input
Configurable boost switch. Enables the maximum output power achievable if the switch turned
on.
12V brake switch input used different port from motor temperature sensor. You can use both
brake switch and motor temperature sensor functions at the same time on the latest version. Pin
25 is 12V brake switch input port.Pin1 is motor temperature sensor input port.
 KLS-HC controller included the fuse and shunt on the case.
Kelly Controller - Features
Intelligence with powerful microprocessor.
Synchronous rectification, ultra low drop, fast SVPWM and FOC to achieve
very high efficiency.
Electronic reversing.
Current control loop.
Voltage monitoring on voltage source 12V and 5V.
Hardware over current and voltage protection.
Low EMC.
Thermal protection: current cut back, warning and shutdown on high
temperature.
Configurable high pedal protection: the controller will not work if high
throttle is detected at power on.
Current multiplication: Take less current from battery, output more current to
motor.
 Process
The conversion process is shown in figure. The
gasoline engine, tailpipe, and gas tank were
removed. The clutch assembly was removed but
the existing manual transmission was left in
place, although the clutch is no longer needed.
A new BLDC electric motor was bolted to the
transmission with an adapter plate.
An electric controller was added to control the
DC motor. The controller takes power from the
batteries and delivers it to the motor. The
accelerator pedal is hooked to a potentiometer
that provides the controller with the signal that
indicates the amount of power to be delivered.
The controller can deliver zero power when the
car is stopped, full power when the accelerator
pedal is push all the way down, or any amount
between.
Process-Transmission
A transmission is a machine in a power transmission
system, which provides controlled application of the
power. Often the term transmission refers simply to
the gearbox that uses gears and gear trains to provide
speed and torque conversions from a rotating power
source to another device. There are three types
transmission i.e manual, automatic and emi-automatic
transmission. In the Maruti Omni car used there is
manual transmission which is not removed from the
car to provide gear system to the car same as before and
without extra custom gear.
Process- Steps
 Disassembly of Mechanical System: Successfully removed the engine, gas
tank, exhaust system and other related parts but the manual transmission part
is not removed as it is going to play the same role of transmission in the electric
car as before.
 Wiring of Kelly Controller with BLDC Electric Motor, Throttle and
Batteries: Tested the standard wiring of Kelly controller(KLS7245HC) with the
motor, batteries and throttle to run the motor correctly using wiring diagram of
standard KLS Controller to ensure the running of BLDC motor without
damage. The image below is wiring diagram of KLSH Controller
Using above wiring diagram of KLSHC Controller we successfully connected. All
the wire and hall sensor were connected to test the running of bldc motor
without damage. The image below is the controller connected to bldc motor,
throttle and battery pack.
• The positive and negative terminal of battery is connected
to B+/Red and B-/Black terminal of controller
• There are three main wires in bldc motor which are green,
yellow and blue wire where green wire is motor to
controller, yellow is controller to throttle and blue one is
controller to battery. The Kelly controller have three
terminal U(Green), V(Yellow) AND W(Blue) for these wire
• There are 3 hall sensor in Kelly controller: one 6 pin and
two 9 pin male and female hall sensor.
• 9 pin male hall sensor is connected to throttle and the 7
number of 9 pin female connector is connected with the
positive terminal of Kelly controller.
• 6 pin hall sensor is connected to bldc electric motor and
having a connecting 6 pin hall sensor.
Assembly of all the electric component connected
together:
The motor is right now in process of fabrication which
involve cutting, bending and assembling
The fabrication process will be discussed and shown in
details in my further work of this study
Tuning Procedure
For tuning we did Identification angle
function for KLS controller before running
the motor.
Downloaded and installed the controller
user program in our system.
Key switch is turned on so that the
controller can get power supply from B+/B-
and Pin No.7.
Opened the user program in computer and
clicked Read button in user program. You
will see the first picture of user program.
Checked whether the Identification Angle
item is at 85 or not. It is correct if
identification angle item is at 85.
Then filling 170 the identification in user
program.We will notice a reset error
message on computer
Mathematical Computation
In this computation we prove through a good
guestimate that the operating cost of internal
combustion car is almost 2.5 times the cost of
converted electric vehicle.
Total cost that one has to bear in electric vehicle
conversion is Rs.45,000 + Rs.45,000 = Rs.90,000.
Which implies that this process is economically
profitable over a period of 5 years.
Results and Discussion
Successfully converted an electric vehicle which is Maruti Omni in this case with a design which is highly
efficient, controllable, durable and has very less noise generation. The design of conversion which uses
BLDC motor and Kelly controller is currently best for the market mainstream as it has optimal cost of
conversion and it is highly efficient. This process can be used in many ways such as public transport
covering a smaller part of area like university. Or smaller routes which are frequent and only longer route
buses travel there which does not meet frequency demand of public traveler. This can also be used in place
of the original Internal Combustion Engine vehicle by this design of electric car conversion as it would be
environmental friendly , financially better option than running the internal combustion car.

It was successfully shown throw guestimation and current value of equipments and petrol price that the:
 The cost of operating the gasoline-powered vehicle is almost 2.5 times the new converted electric car.
Financially converted car is economical and profitable over 5 year period of time is total cost operating of
internal combustion vehicle (Rs.111560) minus the total cost in electric car conversion(Rs.90000) over 5 yr
span will be Rs. 21560

Also successfully completed the tuning procedure before starting the motor which is necessary to do
before starting the motor so as to be sure that all paramaters mainly speed and torque are tuned together.
The correct identification angle for this motor is set to 85 by makers of this motor and it comes out to be 85
which shows the identification angle operation is successful.
Conclusion and Further work
While the Electric Vehicle Conversion project is based on a century old concept, the
innovation in which we have applied to the vehicle makes it more unique than any
vehicle currently in the mainstream markets. The design of this vehicle which uses
BLDC electric motor with Kelly Controller allows for fewer moving parts, which leads
to higher efficiency, controllability, reliability and low noise generation. Finally, our
paper provided a brief overview of the process and electrical component used in the
process of electric vehicle conversion. Through proper programming, traction control,
electronic braking, and other marvels can be accomplished. Communications take
place through a bus specifically designed for an electric vehicle such that all
electronic components can communicate with each other effectively. This paper has
provided an in depth review of the research that has influenced choices in the design
aesthetic. The Electric Vehicle Conversion Project hopes to present the familiar
concept of the automobile in a new, environmentally, and economically responsible
way.

The assembly or fabrication process is yet to be finished and will be discussed in

details in my next thesis.
Thank You and Regards