Retrofitting of 4-W | How to Transform Conventional Vehicle to Electric Vehicle

Retrofitting of 4-W | How to Transform Conventional Vehicle to Electric Vehicle

Team to confirm about this okay so uh hi everyone let me introduce myself I’m Lisha basantani I’m the head HR at uh DIY Guru I take care of all the trainings and placements at the uh at this institute and we are into the EV and e-mobility Training Institute

As you all know about DIY Guru and uh today’s session is about the future is electric Exploring Careers in electric vehicle technology this is the top topic for the day and um we’ll be starting the session within five minutes thanks for joining and if you have any uh questions

If you want to interact something if you want to have any clarifications to your doubts you can ask in the Q&A session that is for last 15 minutes and apart from this if you want to ask from me anything you can just chat uh drop into the chat box uh yes

David uh I’m sorry I wanted just to put an Emoji i i ra my hand instead I’m sorry I no issues please tell me that uh if this is the same uh what we were asked to join the webinar on retrofitting of four wheelers sorry uh is it is this session regarding

The retr of four wheelers the weinar it is yeah fine so our speaker will be joining soon and I guess by 7:35 we’ll be joining the session till then can I please know from where are you guys joining today you can drop your city your country your state anything in the chat

Box so that I can know I am from Delhi Delhi is the headquarters of DIY Guru and you can hello’ you the same person we met in noon I was checking the session yes yes ma’am okay hi nice to see you here December Bangalore Pune biar alaria Chennai indor oh my hometown is

Indor I’m from indor basically Andra Pradesh vasi Delhi Hyderabad okay we have students from India very nice Bal Andra Pradesh jur utak okay Nigeria very nice Nur oh there are so many SS I can’t read even indor where okay I live in indor near to Silicon city um at AB

Road and I’m working here in Delhi aabad okay solapur Neal you’re from indor or pamur indor indor proper indor AB Road the way that goes towards ra SAA yes please tell me ma’am can you tell me about the procedure of placement procedure of placement okay so the procedure of placement that we have

Here at the guru is uh we bring down the opportunities for our students that is screened down by us we either visit to the company or we discuss with the HR and once it’s done we post the job destion on our LMS portal that is courses.

D.org and from there you can access to the jobs whatsoever you are interested in you can just apply to it we’ll be screening your resume if your resume is uh having any uh shortcomings like uh it’s not good in format or we need to change the photograph or Linkin URL

Anything I’ll be reverting back to the mail itself and uh then uh we’ll be uh sharing your resum to the recruiter they will be continuing ahead with your um with your uh interviews and all okay so if anyone is there from di grou team do we have have the speaker with us can

I transfer the call to him pradep Dan you have a lot of questions okay one by one you can unmute yourself and you can ask and if there is something like Q&A so you can wait uh for the end for for ending this session so what are the opportunities

For the placement for working professional for working professionals we also do have opportunities the ratio you might consider between 60 to 40 60% is for Place uh 60% for freshes and 40% is for experien and we do consider the opportunities which will be considering your past automobile experience or your

Past mechanical experience into this okay so I guess Mr jav hi hi Hi how are you good evening evening how are you I’m fine okay great so uh students we have Mr Javad with us he’ll be continuing up with your session so I guess uh I can hand over this call to you

Now uh sure thank you so mucha for the introduction hello everyone good evening good sir uh so uh we we will start the session today before that I think uh is there more people who are joining or uh uh we can start we have 120 plus you may start okay so

Uh uh before I start ma’am yes ma’am recording video will be available after the completion of recording is done but is is it sharable or not that my team will discuss and we’ll let you know till then at least I guess we should start with the live

Session because he is here for a limited time so I guess we should utilize it first and then we can discuss everything in through the Q&A that would be in last 15 minutes yes please sorry for the interruption Mr tbab uh D no worry uh

You can connect me on uh LinkedIn I can you know if there is any question I can answer you so we start with the session today and I will share my screen but before that I think all the people who have joined today’s session it is more regarding the you know retrofitting and

Uh about the EVs and I think you all have the knowledge of e basically because if somebody is not with that uh then it will be a little difficult for them to understand what exactly this uh this industry is so I will share my screen and uh hope you will get a good

Knowledge and good uh uh clear I can say the tech what exactly it is uh sure rafik I will tell I I will tell all the things uh I will let me share my screen I can tell you what exactly today’s session will be about

So Leisha is it visible and my audio is audible like everybody can hear yes you are perfectly Audible and your screen is also visible okay if somebody lost me please let me know maybe there is Network issue so is it visible so I’m sharing my screen

Uh so today’s topic uh is about the retrofitting of the four wheelers and uh if I tell you about what exactly it is uh I have to just go with the very Basics what does a basically EV mean uh so uh everybody’s comfortable English or Hindi so I will go with both

To get things more clear uh so pleas language oh sure sure definitely we can mix the language because we do have National plus International students so everyone would be able to yes yes that’s why I I just saw yeah yeah English would be okay for everyone yes yes uh so the today’s

Session we will the content uh the table for content for us today is that what the what does the E basically means what is the retrofitting retrofitting how how it is you know uh come into the market how it come into the industry we can go

With the overv of the IC engine to the electric because retrofitting is more about the existing vehicle to converting it to Electric so that is one thing we will go with the technical aspects because technical aspect means the how things has to go with the you know the

Motor controller everything how it has to be go with the uh the numerically the theoretically with the quicker because we have the big challenge that is to convert a old petrol diesel CNG car to Electric we’ll go with the battery system and this is the most challenging

Thing in the whole EV either it’s a new it’s a retrofitted it’s a bike two wheer this is the most challenging part and is the most expensive part in the in the whole EV then we go with the performance and efficiency how it perform how how the efficiency go because you know the

Vehicle which we have to make it is more about the performance because banana uh you know it is not something which we can do it because if you if you go with the uh you just you just open the YouTube and search there the how to make

A patol car to elect you get a lot of you know content about this thing but that we call a jugar so we have to go with the all the things how technically all these things work how the science how the Logics work with this so we will

Uh we will go with this whole system and then the safety and regularity consideration and this is the I can say the most crucial part because nobody talk about this because uh what we call it key uh battery motor controller electric that is not something which we can talk about

Because safety and regul is the more important thing right now environmental impact definitely uh we are talking about the EV it is having a good environmental impact we’ll just go a little more deeper in this cost analysis because if we want to oh you know go with this business this this industry as

A big you know scalable industry in the future or even currently so what the cost analysis and then we’ll go with the case study that is our own the tpol like how we work on a one product and that that I can say after that a question and

Answer so I think whole the table of content is clear but before I start with this uh introduction and all the other topics you have been you know go with the about the EV content what exactly it is so uh if I start with this thing why we

Convert the IC engine vehicles to Electric this is the more important question currently and uh if I talk about what exactly it means is that you know every every time we talk about the people or we talk about the people who are talking who are you know jally the

Media and everything we’re talking about the EVS uh Tata has made new EV Tesla has made new even Hyundai has made new e but we know we never talk about the old Vehicles because you know if a person if if if a person is owning a petrol car if

A person is owning a diesel car what about that one we are not talking about we are talking about the new industry we are talking about the new tech which is coming to the market but not talking about the uh those Market those Vehicles which are already in the market

That is the one point and the other thing is the importance of reducing carbon emission because you know the vehicle which is currently inside the city cities people start making you know pictures and they start uploading on Instagram and Twitter that we there is this is the clear sky yam s so carbon

Emission is the important part because it plays a very big am big role which we go into the next slide and there we can see how it impact so I English sir why you are okay okay okay no we are all from South India okay okay

Okay no issues no issues so we we will just start with that why convert why we have to convert the IC engines vehicles to electric power why why there is a need because everything which is in the market it comes comes with the need because if you are making you know

Currently right now a new device new technology that is that it comes with the need and it comes with always a problem so yes it reduce the environmental impact because if you talk about any vehicle let’s take example of Swift desire it is emitting 3.6 gram of

Carbon per kilometer so we whenever we try 1 kilometer of any any petrol car with a 1200 cc engine it emits 3.6 gam of carbon that is one part and the other part is not only the carbon dioxide which which is in the environment there are the nitrogen oxide and NX and the

Other partic matters which are currently you know uh in the in the whole city if I talk about especially Delhi where this is the most uh most I can say the viral City in if whenever the Diwali comes so we see the lot of news about this city

And the Energy Efficiency because if you compare it the other part is the Energy Efficiency if we compare it with the petrol petrol to the electric we see a big difference because it is a very logical it is very you know uh I can say you have all the people have uh

Experienced this thing that electric cars electric vehicles either it’s a two wheeler three-wheeler fourwh they have much power and much better efficiency than the fossil cars and the other is the cost saving and yes it is it is very clear that if you drive a electric car if you drive any any other

You know vehicle we make you know we save a lot of money because running of the cost uh cost running for a one vehicle for an e is one Rupee even less than one rupe per kilometer so that is the big difference if you talk about with the you know conversion of IC

Engines to Electric then another point which we have is that quite and smooth operation because the vehicle which is in the petrol diesel they are making a lot of noise when we convert it to Electric they are very smooth and they acquired basically whenever I talk about

The E and whenever I talk about the retr fitment these two are the same you have to always remember this thing retrofitting doesn’t mean you know it is some new tech these both are same only the difference is the chases in the new e you have the chases there in the retr

Fitment you have the chases you know already there in the new e you have to make only difference in the in this technical term I can say Energy Efficiency is definitely there because it it is the you know the electric motor are more efficient than the combusion engines and the significant amount of

Energy significant amount amount of uh you know production of uh electricity compared with the burning of fossil fuels is more so we can have a better efficiency energy in terms of the uh in the terms of reduction in the terms of the power proportion and the energy Independence and security because

Electric vehicles can provide powered with a variety of energy source because you know if I talk about the IC power car there are three options petrol Diesel and CG even you know some lpgs and other gas gas we can have but in the uh electric motor if I EVS we have a lot

Of option yes the source is electric power but it can we can get it from the solar we can get it from the wind we can get it from the hydro we can get it from the coal we can get it from the nuclear so these are the different kind of

Independence because we are not dependent on one kind of fuel and the technological innovations because in the Eevee we have the lot of tech if you talk about from the past 10 years we have seen a lot of difference in the E especially in the tech part we

Started with the single gear we have the four-wheel dve we have the crab walk kind of vehicles we have the we have the lot of tech we started with the if I talk about in Indian market we started with the 48 volt in 2013 Reva came with

The the uh with the with few EVS which are E20 Mahindra Rea sorry Rea then Mahindra bought it in back 2014 I guess so they came up with 48 volt of system so we have a lot of technological innovations so these all things which I’m talking

About it is basically why there is need because anything in the market it come with a need without need without a problem which we have to solve these things never get you know mature and things never get a big opportunity because for the past two 300 years we

Are burning fuel every day we have made our planet very you know it is not better for living for humans so now we we talk about The Greener energy we talk about lot of you know carbon credits we talk about emission reduction of the carbon gases carbon emissions so then it

Is something which we have done it in the past we are looking for something currently and these are the solution which make our uh whole ecosystem better so this is some introduction why there is Need for this and how we have to solve the problem now we come up with

The IC engine our view to Electric conversion so basically how it how IC engine involve what are the components inside the retrofitted vehicle and how we can con convert it to to the to I then to electric and also we will uh see what are the benefits of electric

Vehicles compared to the traditional as I said in the past slide so we will just go through these slides and we can know how it works so now I have to make a electric car let’s take example we have to work on uh Honda City or any any other

Vehicle so first of all what we do I don’t have to open a YouTube and I don’t to go for how to make a Honda City patrol car to Electric no that is a you know jugar I can say that that is a total jugar solution that is a jugar

Approach we don’t have to go with that we have to go with the proper approach so first of all we will do the assessment of the planning first of all we go with the what kind of the specific model we are looking for how it is

Visible and the live uh uh example I can say currently is that we we go with this phase where we were converted the commercity C-Class to electric and that is you know something very challenging because there is no petrol you know there is no space for the batteries and

Is very challenging because it’s all sporty vehicle so that is something the feasibility the assessment we have to go with the which kind of specific vehicle model we have to go with we have to start with and the other thing how we work is that the factors the age the

Conditioning the weight and space avability for the batteries and electric component these are the approaches basically Tad works this is how tadp start the things and how it go with the proper model and how it works so when we go with this basic like the what kind of vehicle we have to

Convert and uh what kind of you know what is the vehicle age what is the condition is it trusted is it you know the drive train the tires everything is okay it is it smooth or not and is there a space for batteries that is the most

Important thing because we have a big challenge here is that we are working on the retr fitment and in the retr fitment there is no space you know easily you will get for the batteries if you making a new e new car there you can design the

Space as per your you know battery size but here you have to make the design something which we can develop which we can integrate inside the vehicle and after that we have to determine the goals exactly what we have to do what we have to make from this because we are

Not talking about a college project we are not talking about some kind of you know video which we can upload in the social media we are talking about a proper business and uh you know going to the component selection I will just go with my uh what what what what I do what

Basically tadpool do so I started tadpool projects in 20220 and till now we uh in in we started with a vintage retr fitment so we converted the first vintage car to Electric uh in it Delhi and after that till now we have converted 15 vintage car across the country and also recently

We have worked for the Indian army and delivered the gypsies to them and this is the something first time in Indian army the one startup has given this kind of solution we also give our solutions to national parks and also we had a big collaboration currently with the fleet

Operators and uh we were also a technical partner with the action construction to develop 30 ton of electric crin we are not the first one in this market but yes I can say we are the first one who started the uh new industry new you know approach with a good results and

Uh we have the challenges every day and this is I’m just talking in this session I’m talking about how uh I think how tful work and how we take this thing uh you know work on a on a model and how we take things very uh I can say the Clear

Man in a in a particular steps to make it a sustainable viable and scalable business so coming back to the component selection so uh component selection after that when you have the assessment and planning which kind of vehle we have to go with and then it comes to the

Component selection and there is the main important thing you have to select an appropriate electric motor which means there are lot of option in the market if I talk about the motors if you a person you know many people know about the motors but for the other people I

Can I can just give a very small brief over the motors a motor is basically which converts the electric power to Mechanical and there are lot of options in the market usually for the electric vehicles we go with the induction we go with the brdc we go with the pmsm and

Currently the SRM is in the market so these are the latest ST which I’m talking about although it is a very vast project and uh you can read it on you know Google and you can have a better Knowledge from that so once the assessment and planning is done we go

With the motor what kind of motor we have to use what kind of size what is the desired performance characteristics so if I have to work on the Honda City so first of all from my mind I have to make this Honda City either better than

The patrol Honda City or I have to make it a similar to the electric Honda City so first of all that thing has to be very clear and sorted it is not something which we are making Honda City to a IRA so that that thing is very clear and after that the

Second thing is the what kind of range I have to go with if I go currently in the market if I compare my vehicle you know with the for like a Honda City if we have to make it electric we will go with what kind of the nearest electric

Vehicle which come into the into this radar of Sudan so tar is there uh we can have when e Mahindra Vito is there eito so there we can have a range of30 160 kilomet that in between we can have the range and the same we have to

Go with because you know if we can’t give the better but if we have give same similar range which is currently available in the market because the customer acceptance is as for that that so we’ll choose a sustainable battery pack which provide a sustainable energy capacity and the voltage and the range

Definitely and here is one more twist when we talk about the you know battery and we talk about the motor so motor we have the bmsm induction the SRM BLC in the battery pack we have the lot of choices like definitely we would go with the lithium

Uh pack lithium battery but in the lithium there are lfp nmc you know uh there is one more chemistry lto graphine there another chemistry uh it is not from the lithium but in the lithium there are these chemistries which we have the options are so we have

To go with that and voltage why there is the voltage I have written here the voltage plays a specific role because you know if you go with the let’s take example of Tata tigor we have have the 72 volt system there if you take a

Example of the new Tor which is in the market tago there the voltage is 384 volt now the question arise the same vehicle with the different voltages how how what does this mean it is very basic like I you you go with the you know the

Losses is in electrical terms we talk it is equal to loss is equal to i s r IR scare sorry so basically it is the the more current come from the flow from the wire the more it get heed so voltage play a very big important role here what

Kind of voltage we have to choose so we Les we choose with the 72 volts then we have to go with the components what kind of controller we have to go with what kind of charging system we have to go with so our approach here when we have

To go with the component selection we have to very clear that we have to work same what OEM thinks we have to make a vehicle which is already in the market similar to that below that there is no sense to making a vehicle because customer perception is you know

Something he he you will get you will deliver him a brand new vehicle with that performance so below that there is no sense to make a car electric as a commercially then we talk about the integration and installation so the integration installation is a very you know important thing and it is something

Which which where your designing skill and and to be very honest with you whatever I’m talking here about the assessment about the component designing it is not a one person game it need a different domain of people who can work on the different parts who can uh you

Know uh work on the different things but yes you can have the access and knowledge of all the how it works basically so the integration installation is basically how you can integrate motor with the gearbox you have to either you have to run your motor your vehicle on the same gearbox

Either you have to make a new gearbox and either you have to make the direct shaft so in our case in the tadpool case we run the vehicle currently on the manual gear and the reason for that is that for the gipes which we deliver to the you know national parks and Indian

Army there the need is that they want a 404 transmission there so for that we use that gearbox we integrate that gearbox in s that in in a very similar way how engine behaves the our motor mimics that thing so I can’t share the pictures here because it is for the

Patent so for that reason I have not added the designing design here but uh you can uh um I can show give you the idea in the upcoming slides and about other things that uh chases part that how we have to modify the chases because it’s a packed

Chases where we have to cut where we have to put a drive t where we have to use put the batteries that is the important you know very challenging part because let’s take example that if we have to install a 23 kilow of battery which means 72 volt 300 D so where we

Can place that battery either we have to space there no there is no space so how we can install there the designing come you have to go with the designing part how where we have to place that thing you have to go with the 3D we have to R the 3D of the

Then in the solid works and the in the basic software is the solid works where we can just go where we have to exactly place the designing is done by us because in the market there is no batteries for the four-wheeler which you can get easily so you have to go with a

Good battery player and you have to design by yourself then it comes with the wiring and the control system and this is something where every people you know you know they just I can say miss this part it is something kind of a English paper in the board exam where

People think we can get you know pass very we will pass it very easily but no wiring and control system plays also important role because if the wiring is not proper if the wiring is not as per the capacity it will get it will melt

Easily there is a full you know I can say 99% chance for a shock and I am the victim of that shock because there is one wire from the contractor to the controller there we use the 16 mm wire and logically we have to use a 70 mm of

Wire there so that wire melt and we I get the shock when I open that box so that is something why I’m talking about the hardness because in hardness is something when a motor is at the full Peak full Peak power when you are just drawing the full Peak from that there

The motor behaves double off his capacity and the current is very the flowing of current is at the very high rate and you need that thing the wiring is definitely as for the calculations what you have to go with and it is not only for the motor it is for the battery

Pack and the other subsystems because it controls and ensure the functionality of the performance we are talking about the EV and the wiring is the backbone and then it comes the most important thing which I mentioned earlier that safety and compliance if you have to make a now with the

Question arrives here that okay there are a lot of player in the market who talk about EVS we make the electric car in the YouTube you see the lot of player they said okay convert your car to Electric this is the battery this is motor I have done this but you know when

You make your vehicle to electric and you just you know take it for a drive your vehicle will get seized very easily the reason is is it has not done the compliances any vehicle any any kind of car vehicle anything four-wheeler two wheer if it is in the Indian market also

In the other Market European market UK Market they have to go with the safety and the compliances which means they have to go for the homologation the certificate part which in India it has been done from a and IAT and then there are a lot of other you know agencies also which

Take a lot of money so the vehicle you are making it has to go it has to be as per as123 you have to you know follow all the ISO standards you have to follow all the test you make your vehicle you give it for the IAT Ari here you have to

Give the 20 rupes of fees per model and then you will get a certificate that this vehicle has been certified under the IAD and a and then you can register your vehicle under the RTO here most of the people fail because we make the car electric you know for the IC engine

There are 30,000 Parts but for a electric engine you know electric power car there are only 10 15 parts so anybody can make you know for the even engine there are you know 500,000 CR of investment to make a one engine and for the motor there is no you know you can

Get it from any big player or any good player so making car electric car it looks very easy but in it comes to the safety and the comp L spot here everybody fa because you have done the jugar from the starting and here jugar don’t work here your engineering your

Calculations your performance your even a single switch you have used that works and when you go when you done the compliance part then it comes the performance testing and now it comes the another big part that is you know in Hindi we call it d p Pani because

Customer is a judge you have spend a lot of money you have spend a lot of you know time you have choose one model you come with that part but then customer is going to use that part like you have to sell that car you have to sell you know

You have to make your customer car to electric and then the customer is your king he decides is this vehicle worthy or not if the performance is not good if the testing optimization good it’s a fail product although you have done the compliance or not so from the starting

Part from here assessment and planning this is I can say 80% of your work because without that this whole all these steps are you know doesn’t make any sense and when you do this performance and testing then it comes another part which is the documentation and certification and this is

Something which go with the RTO level because when you go with the also the RTO level and with the customer level after getting the IAT and a certificate you have to register your vehicle at the RTO level from where a state district level you know RTO can register a

Vehicle with the new number plate and there is another category called X EV for the vehicle which you retrofit in the government with the you know the uh the gusset which has been released by the government A1 12 123 which is the compliance basically so there in the

Gazet you will there is very clear meure that which the vehicle which you convert you have they have given the new name for it it’s called The X XE why because it was first it was first Patrol now it come to Electric so it’s a x EV category

The retr fitment basically means the X EV category as per the government rules and once the certification the uh registration RC is done then you have to go provide with the basic knowledge to the customer how the component specification the log book the book in which the all things are mentioned the

Wiring har as the component uh selections the uh necessary and the certification regularities all the things have been covered in that so when you go with all this thing now customer has taken the vehicle the vehicle is good the performance is good the compliance are done then it comes

Another important part that is the maintenance and Sport and you know we are we are in this country where the people are the need the value for money if there is no maintenance support still your product is failed so you have to go with the proper maintenance proper sport you have

To go with the you know tracking of the vehicles through iot and recently we have work on our own system we track the vehicles which are running we read the pattern we are working on the few AIS currently in which we can predict the fault because you know running of the

Vehicle is important and if your sport is good your maintenance is good then you have made you know all that is not Tesla but you have make a Toyota and your goal should be very clear that don’t repair until it is not broken this is basically a Toyota I can say the

Slang but they always called it that don’t repair until it is not broken so same thing you have to go with u tag you have to very confident what kind of motor I have done it is as for the logic it is as for the tech it is as for the

Things which I’m talking about then it the next part you know the in production it is next part come about the compatiability assessment basically when session I’m talking about the these things very in a more I can say deeper way so here you can see the Gypsy which we have converted it is

A very rough diagram here it’s a very solid work 3D so you can see here that this is the motor here my I can if you can see my cruiser here so so this is the motor which you have coupled with the gear box and this is the uh

Fabricated box in which the control every part is there and here you can see the battery pack is something which we have placed here and the people who know about the Gypsy the gyps is on the lader it’s a later kind of chesses in which there is only space here either here or

Either in the front so front part we used because the requirement of the client was to make it 4 or4 as well so this vehicle is running on the electric gear and is running on the 44 transmission as well and the battery we have placed here it we have designed in

That way that the weight of the vehicle should be clear should be balanced and the height width and everything has to be very clear so in the next slide I have given about the designing of the battery which we have done for the Gypsy so it is mentioned there so you can just

See from the 3D how the things work it is not something you know to jugar you can do you can click the picture to go with the proper single detailing of the vehicle when I talk about the vle condition is the chess’s body it plays a very important role here also in this

Thing if just if you just take example that this part you know this part the uh fer side the lad side is not good then this battery will get damaged very easily because this battery for the Gypsy fades 180 kg yeah there is one more thing which I forgot that is the in

The as you can only add the weight 25% of the vehicle like the unladen weight if it is 1000 kg the government only permits you to increase 25% of the weight of that vehicle so the designing everything has to be clear as per the rules and now if I talk about another

Part that is the the bearing the tire the chases because you know making a new E is easy for me but if I think to work on a old vehicle I think it’s the most challenging thing in the world because you don’t know about the tires you don’t know about the

Chases because everything is has driven for lack of kilometer so this is the most challenging industry currently in which we have to go with a good product and good parts here I can give one uh one of my experience that when we deliver one vehicle to in a

You know park there we see that uh we tested the vehicle here and there after some time around 15 20 days the vehicle is not running the the person who who was driving the vehicle he said that whenever I’m driving the vehicle it get turn off very easily like it is getting

The the batteries getting disconnected whenever I press the pedal so you know the maintenance sport part the it cames so we were very surprised at how how this thing is coming up we have tested the vehicle then from here we can’t say anything because that time we have not

Developed any iot any telemetrics from where we can track the data and we went to that place and you know when I drive the vehicle uh whenever I press the pedal it start you know taking a little uh acceleration and it get disconnected and when I connected our whole system with the you

Know through can where we can get the data so everything was was okay there is no I can say nothing where I can suspect we check the whole battery whole motor whole controller we are not getting the how you know fault where it is coming

From and when we then I I just go with the very basic okay let’s take this vehicle from starting you know how we make we check the gearbox we lift the vehicle first first we check the gearbox in the neutral it is running fine we check the transmission it is running

Fine then I talk uh then I called my one you know one engineer I told him that okay take this to this uh vehicle on the jack and run its tire for at least 40 minutes so when it start running there we see there is a lag in the tire

Between you know from for left side and the RPM is not matching the another the tire which is for the right side and here I get the you know I suspect that there is something in the tire so when we open the tire we see the bearing was

Totally faulted so the bearing was Jam the tire was jam and it is why the motor was disconnecting again and again because I have set all the you know I have limit the currents all the peak current Peak power in such a way that whenever there is so much load the motor

Will automatic until it get disconnected so there you find the you know fault in the bearing so that’s why this thing very uh you know important for us that the vehicle condition the chases and the drive TR components it is very important for us because we’re working on an old

Car which have been driven for you know lack of kilometer and the space it is definitely the battery you have to keep because there is no space and uh in the Gypsy we have not you know there is I can say not even a 1 inch for us where we can

Increase our battery so that is the thresh where we have make our batteries bigger in the size and bigger in the capacity so that is an important thing also another thing here is the we distribution and balance because if your whole system is at the back the

Batteries you know at the corner and from the front side the components are not that heavier then there is the hammer effect effect in the vehicle you can see the hammer effect whenever the you know uh in especially in the Seesaw light kind of thing when we uh Drive the

Vehicle there will be the hammer effect and it is because of the battery pack because I told you the battery P pack weights around 180 kg so that is not a joke it’s a very heavy and it’s the same for that that capacity is the same for

Everybody so that is something which you have to go with the distribution of the weight because you have to check my CG center of gravity is good my rolling res is good is it you know making Worth to make it electric with this design or is

It you know something of Burden I have put it on the body or on the vehicle another is a dve drive TR configuration I told you earlier that how you have to connect the motor with the drive wheel either it’s a fun drive Drive is a

Rear drive you have to if you want to use the gearbox you have to go with that couplink where we call the flench coupling but you have to design that part you have to just mimic how motor behaves it is something I can say the

Trick which we have which I I know just replace the motor similar in the similar way as your engine behaves and another thing is that the layout of your electric motor design everything how it works how it will get couple the clutch is there if you want to use the

Drive for the single gear system in that you make it a full automatic you can do that as well but it I told you it totally depend on the client and the type of the vehicle you are working on now there is one more thing in that

Vehicle when we you know uh this SC The Experience I’m sharing is that when we check the Tire of the vehicle we find that the bearing is totally damaged but there is one more important thing which I noticed during uh the uh the data which we which I was tracking

That the temperature of the motor goes above the 100 and the controller temperature goes to 60° C which means this vehicle is getting heated that time we have not done any cooling ventil cooling system in the controller part because we were you know working on a

Very basic we just think okay it can run but that that in the it was basically a hotter City so the temperature is very hot and then we find that okay what what ha what is happening there is that when we are driving the motor the vehicle in

The first 40 kilomet it is running very fine but after that the whole performance efficiency is down because the controller is you know making its efficiency down because of the temperature so temperature plays very important role so you have to go with the cooling system we develop our one

System we install the cooling pad there in the controller and the motor from there the mo controller temperature like especially in Delhi there was 35 degree uh 36 degree outside and our motor our whole EV Power temperature was uh 28° C that time so that means it works and it

Gives a better performance to the vle so that is something which we have to work on the cooling and ventilation because a very important thing it is not something engine which requires uh you know 600° Celsius of temperature no the cooler and more ventilated your EV Power TR system

Is the more efficiency and more performance you will get so that is uh the learning which we get from the you know from our basically faults which we done in our past but that gives us a good good result and I’m sharing your my experience with you so that you can also

Go with these things as Sim in the similar while designing a vle and uh the fuse system connector system it plays also you know I can say very tricky role here because uh generally when when we go with any controller or any motor the connectors are basically from the vendor

Side from like if you’re are taking a quare motor if you’re taking any any motor in the market which is for the meant for the EV uh the even for the any control like Curtis the zappy any controller so the the connectors are basically from the vendor side and we

Never you know check them and we just use them but you know the connector plays also important role here it is the same case which I you know another experience there is one vintage car which we have given in another city so there the vehicle is not you know getting

Started so when I visited that site personally there I find that the connector is broken and why it is broken because it is not of the automative grade so connector and fuse plays very important role here the wiring obviously it plays but these small small things because you

Know for that one connector which cost only 5 rupees I have to spend 50,000 for my flights like you know spending Hotel flight two three days stay so that cost very big for me so there is another learning which I got from you know the real experience that connectors you have

To go with the automative grade either your ventor is providing but you have to check it it is worth it or not and when you are talking about the upgradation modification for the higher voltage higher current you need the another you know components look DC direct current AC alternative

Current if I talk about which current which current you know is the more dangerous the answer is DC but if the voltage is high in the AC you will get a chance you know you get free but for the DC it will just make your you know total

I can say it will it will make a person total melt into a whole you know in a carbon State the DC is vary and in the batteries we are using the DC batteries at the higher voltage so the component the protection for that you have to go

With that and if we we if if you go with the back uh data we saw a lot of news about the two wheelers fourwheeler that the battery are getting shot the fire incidents so there the BMS plays very important role so look in this session I’m not going with the component level

How what kind of component we have to use what I’m just going with the real world challenges the Integrations and how we had to go with this whole ecosystem so then AIS 5048 was there for the battery then it comes with the6 where you have to make your vehicle

Battery more better you have to take the uh the uh the consideration the cut off temperature you have to ensure all the safety check the AIS which I’m talking currently just write down all the as you can get these automative you know standards a very easily on Google

Internet and from there you can check for better for your knowledge and you can see how what kind kind of changes the government has made so it’s a as156 for the batteries currently and earlier it was 048 you just go with that and for the retrofitting it’s a as1 123 so these are

The as which you have to follow for your any vehicle like as123 which part sir part two so these are the standard which you have to go with because you know this this is some kind of a I can say the procedure like if you had to make a

Biryani so the procedure is you get this kind of rice this is a jira this is elachi so you just mix all the things in the starting you said my Biryani will you know I will get the hyderabadi Biryani so that is not a way you have to

Go with so this is the similar way for the automative standards which you have to follow what kind of wire what kind of socket what kind of switches the battery the motor what kind of test I have to go with the these AIS uh clearly mention all these

Parts so the cost benefit analysis definitely we have to I will talk about this in the next slide also what kind of things we have to go for because you know we are talking about a tech tech tech but we’re not talking about the money there is whole science you know

You can be a good engineer you can be a good designer but if your product is not hitting the roads if it is not available on the road if people are not liking it then it’s a total failure either make a rocket so let’s now take uh the motor

Selection part how we have to go with the you know what kind of motor many people think about what kind of motor we have to choose because I told you that there are lot of options in the market there are um I can say the pmsm pldc induction

So in the if you go with the earlier in the starting we find that induction motor everybody use why the tech is mature and look just remember this thing always go with a mature thing for your full flood product if somebody is doing R&D somebody is saying I making this motor even that

Motor is you know available in the market and he is saying that I’m making this motor don’t take it either you have not test it either the person is not available in the market either his service sport either his you know uh product quality and life cycle is good

Never go for that so in the starting one currently many people go with the induction motor because the performance it is a rugged motor there are no magnets inside and it is something which people want because it is it is a mature Tech basically but then we currently we

Talk about the pmsm in which the magnets are there and you know the difference between the induction and pmsm if I talk about in the terms of AVS for the pmsm why we choose the pmsm first is that it is having a better torque pmsm Motors are having a better torque than the

Induction another is that it is having a better efficiency so efficiency means it is it is 90 to 93% efficient and induction is 85 88 so in the electrical 1% efficiency makes a big difference and the another part is that the efficiency I talk about the torque I talk about the

Controllability pmsm motor we can control very easily for the induction it is difficult and you know the you know twist here is that the controller for the pmsm is cheaper and the controller for the induction is you know costal if you go with the example if uh

If induction motor like a 15 kilow of motor cost 50,000 Rupees and the 15 kilow of pmsm motor cost 50,000 Rupees and the controller for the induction motor cost 1 lakh rupees and the controller cost for the pmsm cost only 25,000 3540 maximum so this is you know

Something which is in the price side but yes pmsm is having a better uh talk better efficiency and better we can control that but the only dearit in the PMS is that it use the magnets in which which which which makes uh you know one more I can say warning here is

That when I talk about that when we visited the place we find that the control motor temperature 100° celi when the magnet goes above the 100° Celsius your M your magnet will get D magnetize which means the power is totally dropped so for that we have to go with

The cooling part so I have to make my whole vehicles ventilated we have to add the cooling so that our temperature e range is within uh that radar where we can control where we can make our shell life better and where we can take a better efficiency and performance from

The motor for the for 100° Celsius in the pmsm motor the temperate the motors are the magnets are you know okay but after that it it is something which will the Heat will demagnetize magnet and in the induction there are no magnet then there is no worry for that so this is

The big difference currently but everybody and even the pmsm is more you know smooth and very uh you know soundless and uh this is something which I talk about from my experience and this is something which I talk about in the technical term and now let’s take an example if we

Have to go with the Honda City so Honda City for that I have to go with the first weight what is the weight okay it is the 1,000 kg I’m just taking example it’s a 1,000 kg unladen weight which means there is no there are no people inside the vehicle

So that is unladen GVW mean gross vehicle weight in which we kept the five person and we just calculate the weight basically it is given by the company by by this side so we have to first go with when we talk about the motor how to

Choose a motor we have to go with the basically the factor weight than the desired acceleration because I told you that okay I want acceleration of the like I started my career from a college project where I made a first electric car it was a you know where I kept the electric Ria

Motor in 201 back in 2019 but believe me the acceleration was too bad like it was just know slowly slowly it start running but the top speed goes to 60 km per hour but acceleration was not good so the that acceleration and the good part about the EVS are that the acceleration

Is better than the IC so you have seen a you have seen a lot of videos where the you know Tesla truck is spting the Porsche and you know lot of uh better EVS are coming with the better acceleration so the acceleration in the AVS are really good uh rather than the

The petrol uh diesel car so you have to go with the desired acceleration so 0 to 100 or 0 to 60 basically we talk talk about I need it in 8 second so that you have in your mind then where my vehicle will use okay it is driving we have to

Like this vehle will go in City this will go in Highway this will go at you know ladak but this doesn’t make a sense because if you’re are making electric know vehicle if you making a vehicle in India then you have to make in such a

Way that if person is using it in kanyakumari if a personing in Andra he’s using it in ladda it has to be compatible with all the states all the region and all the tariffs so that is something you have to clear with your mind then we have to calculate the

Horsepower there is one case study in the next slides where I have given the formula which I used to how to calculate the motor battery I’m just giving the literature part here and we can have a look on the calculation part there then the T characterzation So if I talk about

The Honda or Swift desire so the torque is that if you just go with the you know search in the Google that what are the uh specifications of the Swift if I’m talking about Swift or Honda City so there we find in the spec sheet the torque maximum torque 110 Newton meter

At the rate 2,000 RPM here EV play a very important role we if we are using a 15 Kow of motor with a 110 kilow of torque but the acceleration is not at the 2,000 RPM here the EV win because we can get that torque in the starting RPM

That’s why we have the acceleration really good and we have very good torque we have good power starting for the PM yes induction is also there but pmsm wins here so that is kind of thing the total horsepower the total kilowatt because we are talking about AV is more

We talk about the kilowatts rather than the horsep the desired performance which we talk about then we talk about the talk characteristics what kind of talk we are looking for first of all you know we have to remember we are retrofitting a EV which means we have to make this

Vehle better than the petrol car we are retrofitting a petrol car sorry we are retrofitting a petrol car or diesel car I want IC car to EV so the vehicle was in the you know if it is in the petrol we have to make it in electric with a

Better power like the Swift or the Honda City we have to make better than the Honda City with the performance arrange that is a clear the talk characteristic the factors the towing capacity all we have to calculate in the start and yes there is one more point you know

Uh I will just ask this point at the end because I want to know from you in the question answer round so basically you know you know about this part or not so then the form factors the form Factory basically the engine you know the vehicle is designed as per

The engine where it we have to place the engine where we have to place the patrol tank it is designed basically in that now you know we are putting a soul into that body like it is basically transplant of heart kidney liver in a old body so we

Have to just go with that considering those factors okay this is a engine compartment we have taken it outside here we can use a motor what are the space we have to go with and we have to work on the standardization it is not something which we can work on every

Vehle standardize the things if you go want to go with a scale then the motor form factor the dimensions land bread okay this is space this is where the ventilation coming there are a lot of challenges you have if you go with the designing part because you know placing the motor

Everything you know if you have to go it for a short run it is you can do anything but if you have to make it as a OEM think if you are thinking like a you know Mercedes you are thinking like Hyundai you thinking like Tesla you have

To consider all the factors then you have to uh choose a motor with a good talk with who which can handle the flench coupling the gearbox you have to consider all the things what talk it is it this uh the n in this an you have to

Do the load part how much of load it can bear what is the you know gear ratio I have to go with so that is something which is very vast subject and I’m currently pursuing my Master’s research from I delh in this subject ALS also like in this particular subject because

This a very big subject this is something which I can say in this webinar but this is something uh you know uh the Highlight kind of thing which I I can talk about so you have to go with the all characteristics then when we talk about

The motor type I told you the motor y induction y pmsm but there is also the uh I can say the efficiency part because when we are talking about the induction pmsm and SRM then we have to go with the efficiency because our motor should be

Not like in that manner that okay this is consuming a 200 ampere of current in you know when we are accelerating it so that doesn’t make a sense so we have to consider that part also although it is good it is powerful it has to consume

Less you know energy it should be kind of a Splender where we have to just keep the petrol one lit it has to go for 70 km so that thing you have to also consider how what kind of motor like it a very simple thing we have to give the

Money we have like it is something kind of thing I can say uh value for the money but here we can say it’s a value for the tech value for the technology I can say the technology which we are adding it has to make the value there because a good efficiency good range

Good power density it has to make the whole performance good like uh if you are using 20 kilow of pack 23 k of pack it has to run for under 30 kilm but it is running only for 80 kilm which means your acceleration is really good but

Which means it is not you know uh touching the thresh it is not something which is in the market which is coming with the mar which is in the market available although you have made your vehicle very fast so the uh vehicle usage and the vehicle where it has to go

In the Indian cities it has to very clear so the efficiency and the consumption you have to consider the motor has to powerful but it has not to consume a lot of current so that kind of thing you have to go with now the most expensive part is the battery system and

80% of the cost is your battery in our vehicle I can say if we are selling our vehicle at you know 10 lakh Rupees 7 lakh Rupees is only for the batteries and batteries are the very important thing so when we talk about a motor okay uh 15

K of motor 20 K of motor we are using this is the power efficiency this is the talk okay this is really good power now you have to look you have set the engine but now the question comes what kind of fuel you have to provide because fuel is

The something like you have a V8 engine V6 engine but you are you are putting a kerosene that it will never you know start and if it is a petrol car you are giving a diesel uh you know fuel it will never get started so the fuel fuel is

Something which is a crucial part in the EV because what kind of battery you using if you’re using let’s say in the Reva basically in 2013 I we are having few Ras in our yard so I see there the people that company can use um lad acid

Batteries but if you are using a lad acid battery though how you can get a you know 3C 2C discharge there so that thing you have to clear with that what kind of fuel are using and yes in the market there are only you know currently

The fuel here there is the lithium ion but in the lithium ion there are a lot of chemistries so for Tesla for any company good company they are going with the lfp and same we are using also the lfp lithium iron phosphate so in the battery also it is very big subject because

Battery is something which you have to study from a chemistry level but here you are not doing some you know a PhD or any Masters you have to go with the market so I’m just telling you about what a market how how we have to go with the market

Selection so the if we if we then if you go with the motor it’s at 15 kilow so now the condition for our you know vehicle is that we have to run this vehle for 150 km so when we choose the battery there are calculations in the uh

Next slide few slide after few slides so we have to go with what kind of you know power we have to use if we are using the lfp or we are using good BMS we have done the good designing part here it comes that when I’m pressing my pedal

The 15 kilow motor behaves you know goes with the peak and gives me 30 Kow of power for a few seconds which means my battery is able to provide a double of its capacity if it is a 23 kilow of battery it has to give uh 50 kilowatt of power for few seconds

Or 30 kilowatt to meet that motor so the fuel is very important what kind of fuel are using and the designing of the batter is a very important crucial thing so in our vehicle when we press the pedal 15 K motor we are using if we are

When we are pressing the pedal here you know logically it has to it depends on the load if there is a TR you know slope if there people are inside so the load uh the load on the batter is basically 10 kilow 12 kilow 18 kilow 3 kilow it it

Varies on in that way we get the range but in the starting if I’m giving a acceleration the load goes up to 27 kilow which means the 6 400 aamp of current is drawing from my battery but my battery is only the 300 here the lithium here plays a very important

Because we can have a you know two c rate the C rate is basically if it is a 100 ampere of current we can we can if it is 1 C or 2 we can take out a double of its current from it uh you know the output so on

That part we we if it is a 300 wat 300 ampere of current we can draw 600 ampere at one 2C so this is something which we have to go with the fuel with the battery and then we have to calculate the energy consumption because if my

Vehicle is you know consuming a lot of current then there is also no sense because either my motor is not behaving in a same way what it has to behave because you know the architecture you know the designing part but is not behaving then it is totally you know

Something is missing because either it’s from the battery side or it’s from the motor side and then you have to consider the efficiency losses also because you know you have to just it’s a uh it’s a logical and it’s a very technical thing you have to keep in mind

That every battery lithium battery it has the 20% of the dod which means if I’m if I say Sir this is a 10 kilowatt of battery in actual it is only 8 kilow of battery because 20% of the dod is there 20% DOD it is basically the graph

Three from 3.2 to 2.5 when we go down when we degrade you know consume when we discharge a cell in the 2.7 it drops suddenly like in that sh it’s this is basically behavior of the lithium cell the lithium chemistry basically it is not stable at the end

Point so we take a 20% DOD always so whatever you are having if somebody saying that this is 3 G of pack calculate the 20% deod there it is not the same 20% we are getting there it is the dod we have to C the Deep discharge

Basically so when you uh calculate the battery capacity you have to add the safety margin also now here the one question also you know one tricky thing also if if I if if let’s take example my battery needs uh my vehicle needs for 100 kilomet range it needs 10 kilow of

Battery okay I calculated okay uh from my mathematical calculation I I said I need 10 kilow of motor but I will never use a 10 kilow of battery sorry 10 Kow battery I will never use the 10 Kow of battery why I use a 12 Kil of battery

Because I have to take a margin of 20% because my calculation says that it is 20 10 kilowatt but there is DoD also in the lithium Cell lithium packs So 20% I’m taking a margin to meet that King so in all the battery which you see in the

Tigor Vito anywhere if they say 23 K of battery always calculate the 20% do and after when you and then again a56 the is 58 you have to go with you have to see what are the safety precautions what are the measures which government has mentioned in the

Automated standard we have to follow that we have to choose a very particular BMS because BMS is the most uh sensitive thing in the battery because if you are choosing a wrong BMS your battery will get fired easily you will not get a proper output so the BMS very important

The designing of the battery is very important and uh that is something which you uh has to consider in your mind here is the one example like if we if the vehicle consumption is 250 wat per miles and the desired range we need is the 200

Miles and the efficiency loss is 15% and uh sorry I forgot one more Point here is that when you are calculating 20% DOD but there is the losses also in your vehicle in the retrofitted vehicle even the new vehicle the tire losses uh the rolling resistance the aerodynamic loss

You have to consider that part also so if it is 12 12 kilowatt you have to add a margin of 1 kilowatt also for that to meet up that all losses so these are the loss you have to calculate so here the total energy consumption is the vehicle

Energ cons multiply desired which is a 50,000 wat hour which we have to require for a 200 miles this a very basic calculation we have to go and if somebody wants to take the uh you know picture of this you can take because this is a very good formula you can use

And uh then we have to go with the adjusted energy consumption which I mentioned that 50% of the efficiency loss we need and here you can see the total energy consumption multiply 1 plus efficiency losses you can get this formula very easily on the Google these

Are not some you know rocket science a very basic thing so then required battery look this is something 57,000 it’s a 57 kilowatt battery which we required but I mentioned that we have to uh keep up the battery you know DOD the efficiency also there the efficiency

Factor and all the things we have to calculate so when we divided the adjusted energy consumption by battery efficiency factor which is 085 we will get the desired battery now you can see from 50,000 like 50 kilowatt to 67 kilow which means we the 17 kilowatt is

Added so this kind of you know adjustment you have to do it is not something 10 kilowatt you have to use K no it’s not 3 kilowatt it’s like so better example so we are talking about 10 kilow but it’s not a 10 kilowatt it is basically 13 kilowatt in which we have

Calculated the you know DOD we have calculated the losses we have calculated the efficiency all the fact Factor we have this is the range we have to battery capacity we have to go with this is our One battery design which you have done for the Gypsy so this is we have

Done by ourself the battery design here you can see the cells we are using the uh uh here the 160 is the cell Dimension like this is cell which you get from the vendor he gives you the cell uh uh basically data sheet in which the cell

Das everything is here so we are using the Prismatic cell when this we are not using nmc Tesla is using the cylindrical cell 18650 we are using the Prismatic 100 cell so this is a you know if this length is very you know large it makes a trouble for you in the

Battery fitment so your whole brain is total stuck with this part how I can design the battery where I can keep the battery and believe me without the experience you can’t do this thing because this is something which you get with the experience the battery BMS placement the

Type of connector which you are using the type of wire you are using all these things you have to consider and you can make the battery by your own you can design it and there are a lot of people you know Engineers who design the battery then in this pack we are using

The 69 cells and 69 cells are connected in you know uh it’s connecting series and uh it’s a 25s and we are having 72 volt 300 of capacity and it’s 2 23 kilow of battery but it is not actually 23 we are only getting 18 Kow of

Power so one more case here and one of my worst experience which cost me 25 lakh rupes of you know I can say loss when we are using the Army project there we there I calculated all the battery calculations okay this is the battery calculation we

Need this is something 18 kilow 16 to 18 kilow for client requirement was 120 kilm with full load and with the full speed so that is a you know achievable range it is a practical range with which I’m talking about and in the AR and IAD

Your D your range will be 200 kilom so even it if it is your Buy any two wheeler three-wheeler they always mention uh 200 kilm range there is star and AI IAT they have mentioned so that is the lab report in the actual it is 110 130 so we I’m talking about the

Actual R I’m not talking about any you know claimed or lab range so when I was doing the calculation here then I calculated okay we need like 18 kilow of power we use the 80 volt 200th of battery and when we start you know taking a trial on that batteries we get

95 maximum of to4 kilome of range like if you are driving very good like a very systematic manner the range was 104 you know maximum and I was not getting how it is running we have done lot of you know test we we we wait we we done you

Know 30 Cycles so that cell will get balance it will give the backup but the results are not getting at the end I you know you know doing a lot of brainstorming and you know rectifying the error why it is not giving us a range what a client desired range then I

Recheck my calculation I found that I have not calculated 20% DOD and the efficiency losses I forgot that part and that cost me 25 LH rupes of penalty because I have already quoted some price to the you know Army and then I have to go with the bigger pack so actually it

Was not 16 18 kilow of pack it was basically 15 to you know 14 Kil of pack which was in the uh in the back which which was actually working so now the 23 kilow of pack which we are giving it is behaving as a rtin so this is very big

Thing which you have to keep in your mind because these you know basic basic small small things cost very big for you so charging infrastructure so we talk about the motor we talk about the batteries now we talk about the charging and this is the subject which you you

Know you know very better the home charger is there the DC charger are there home charger is something which you can get charge your vehicle from home with 220 volt it it goes maximum up to 3 kilowatt because our meter is having only 3 kilow of 3.2 kilow of

Capacity so that is the home charger which you have to give we provide the home charger with our vehicles we are taken charge their vle easily from their home switch and another is the fast public charger there you have the charger from 19 Kow 15 kilowatt easily

And you uh charge your vehicle from the fast charger and it you know fast charging is not recommended even by the oems because when you do the fast charging the cell get heated and you know heat makes the chemistry of the lithium very I can say uh it it decrease

The life of the cell basically in a short way so the fast charger is not recommended unless and until you are in a you know for a t or not in the city so avoid that so public fast D fer there are lot of protocols which are follow uh

The CCS the C type two which are the European Chinese which is in the market so these are the few picture of the home charger and the fast Chargers which we provide and also there is one more formula which you have to go with everybody knowe this thing it’s a very

Basic formula like uh if a if my battery is uh you know 10 kilow and a company has given me 2 kilow of charger so I have to charge it home charger basically so if somebody say how much time it will take just divide 10 by 2 it’s a five

Which means 5 hours it will get full charge it’s basic formula everybody calculate you know it is a better for information and the other is that uh if uh if I’m getting you know if I have to charge my battery from public charger the charger is 5 kilow so how much time

I my scooty or my you know three-wheeler will take the vehicle will take so five is uh 10/ 5 it’s a two in two hours my vehicle will get charged it’s a very basic formula now the important thing is that cost analysis you have done a lot of R&D you

Have done a lot of brainstorming you have made the vehicle if you are in a you know company if you are in a good company you have done lot of you know even either it’s your own startup you have done lot of things but the part is that cost

Analysis let’s take example you have made a vehicle and that cost 15 20 lakh rupees why not buy a t Nexon or any new vehicle why I have to convert my old vehicle to uh Electric so that is a big challenge for this industry customer is

A very price sensitive he will not spend because he’s having a lot of option in the market what you are costing him so if for the Gypsy I’m taking example like for me they told me how much Gypsy cost it cost 8 lakh almost what are the

Specs you are giving we are giving a Specs which is similar to the tore so T how much tore cost it cost around 14 lakh rupees and how much uh your your vehicle cost so if let’s take example if it cost you know not example it cost

Around 7 lakh rupees so okay like it is the half of the price you are giving okay good but now if I have to give this cost analysis to my customer this is the Gypsy basic like I have to you know tell him understand him what are the benefits

You will get to when you make your car to Electric the mileage uh this is basically for the maruti Eco one of my client is asking for that so I have made for that it’s not for the Gypsy so for the maruti Eco it’s 18 kilm per liter

Mileage you will get it is what company says so cost for running 100 kilomet is 538 rupees I’m just talking about 100 kilometer carbon emission is 2.6 G per kilometer so you can just calculate it for 100 kilm is 2.8 kg for 1,000 kilm

For 1 lakh kilm it will be in the ton so we are saving carbon and now there are carbon trading in India you can sell the carbon credits you have to register for that that is some another process you can also search it on Google and we get

All better data so maintenance cost for 100 kilomet is 30 rupees it’s like a 20 rupees so fuel consumption if I talk about 100 100 kilm every day for one month is 166 lit so cost for pet controll for 1 month 100 kilom per day

If I running 100 kilm per day and uh what how much fuel cost for 166 lit it is 1 lakh 161,000 66 60 rupees and the carbon emission for one month is 8.4 kg and similar if I go with the one year we are spending I think there is Miss uh some

Error in the one month calculation this I think 16,000 and uh for the one year one year it is 1ak 93,000 it’s a 16,000 basically this is some error and carbon emission in one year we have said 100 kg so this is something you know person is

Spending for 100 kilometer every day 365 days spending 1 lak9 almost 2 lakh rupees for 100 kilomet every day in maruti Eco and he’s emitting 100 kg of carbon so if he converted to Electric so if I’m using their you know 12 kilow of pack for 100 kilometer or 14 kilowatt so

Taking 7 rupees unit electricity unit so it cost 126 to 150 carbon emission is zero maintenance cost is five because it is having very less maintenance electric consumption is 540 units per month for 100 kilometer and uh for uh the electricity cost there it is spending 16,000 rupees here it has to

Spend only 37 00 rupees carbon mission for one month is zero the electric consumption for one year is 6,480 and just look at this number 13,22 for one year 45360 for one year so this is the difference you have to tell the customer so this is your saving if you have spent

A 6 L rupees in your conversion car you can recover your money within 2 three years and fire eight years of the life is for the battery so this is the big difference you have to go with so now the end part of our today’s session is the case

Study so this is a electric crane where we are the technical partner for this and the challenge for that this is basically it’s a F-150 action construction equipment you can see this in the website so it’s basically the patrol version so we got opportunity to with the I have meeting I got

Opportunity to meet with the uh the owner of the company who said that we are working on this and we if you can work on this for the consultation being a technical partner so we start working on this screen so here in this crane it is basically a diesel crane so they said

That what you are doing replace it in here but with a big scale so basically this SC is retrofitted but it’s a OEM product like it is similar way I told you in the in the starting that new vehicle old vehicle you know new EV retrofit e it’s

The same only chases makes a difference so we went to factory we these cranes we manufacture they manufactur in the faridabad pwal so they pull out the engine diesel engine they said now you make it electric tell us how we can make an the whole their team and we uh it was

It took one year for us to brain storm the challenge for the screen was the power train battery load capacity duty cycle gradability compliance charging cycle power train first of all big issue because it’s a 44 second battery because it is not something you know 10 20 kilow you

Required load capacity is 30 ton this whole crane is you know 15 ton and it lifts 15 ton the you know customer requirement is very clear 15 ton it will you know lift total capacity is 30 ton duty cycle what is duty cycle in the construction vehicles their mileage is

Is not something we be require we Count Their duty cycle is Count okay it it it counts for well 13 hours of duty cycle credibility because it will not you know it is not something which which will run on Highway it has to go with the offroad has go in a very different

Train so gradability there compliance because whatever you are making it has to complies will comply with the government rules and government nors and then chargeing cycle so this is something very similar way the electricity is explained how it works so if your wire is less this is V this is

Oh so I can see in this picture you can understand the whole electricity how it works and how what is what does electricity means so for this thing I have to calculate what are the motor I have to I I mentioned in the earlier slide we said

First of all assessment we know then power motor calculation then battery calculation then compliance we go with this calculation you can see I have it’s a handwritten and sorry for the you know my handwriting is not that good so the crane was basically it’s a lifting capacity the client requirement 15 turn operating

Weight is 15525 kg which is 15 T transmission synchrome mesh top speed 40 kilm gril is 40% unladen so for it is very clear that this is the same petrol it is basically on the a diesel engine not petrol uh they want the replicate of in the

Electric I told you the best way to make the car electric is there to replicate the petrol diesel car with this electric power with our electric power it’s the best way because the person is driving already that vehicle in the petrol obviously it will get better if you use

Electric but first your uh vision is there to replicate that they want the same gearbox because they said you have to just replace what your architecture here also so we use the first Hill Climb for this is the mass into gravity into sin Theta Mass we are having 155 25 gravity 9.8

Sin Theta we get from the gradability if you convert the 40% gravity into the angle so you will get the value of 0.366 you will get on the Google easily so this is the force we get it’s a 5576 1.29 Newton so these are the form which

I have basically made it is something you know which works for always and yes it is a basic formula also but this is something you know tricky formula I can say that you know uh some kind of uh I can say uh most uh quick way to understand this so the

Total power is the total Force into speed for the speed we have to take it in the meter per second so 40 kilm was the requirement you have to divide it with the 5 by 18 on the Google as well to convert it to meter per second it’s 11.11 so force was 55

6761 Newton multiply with speed 11.11 you get the 77 kilow of power this is the power you have to require for your motor for your crane to run this is the very simple easy formula I have developed from where you get the power rating of the vle but for that all this

Data has to be very clear but this this these formula vary because I’m talking about the one case study of my crane here the things are different but you can Implement in other also so what is operating weight sir operating weight is 15525 it’s a 15 T basically so total

Weight gbw is 30 T 30,000 kg what do you mean by operating weight the lifting weight this this bomb okay fine yes this is the bomb which it has to lift so 15 ton is the whole vehicle weight and 15 it lifts so when we uh calculate all

This thing we get the 77 kilow of uh power rating it is the desirable rating which we have to go it is the you know maximum because we have taken 40 km per hour speed so but now the things come here that 77 kilow of the power you

Required no we don’t want read 77 kilow of power it is the 77 kilow of peak power we required and this is something which we have taken plus because 40 km is not something which a vehicle will continue run because I’m taking 15 turn of load with the 40 kilomet of speed is

Running which is not practically possible it can never run on that but in the calculation we take the worst of the worst as I mentioned it cost me already 25 lakh rupees in the earlier so this is 30 this is 77 kilowatt of power which required and for that we this is the

Peak and we are having in the India we uh with the one company we develop the actual half of the motor that is 37 Kow of motor with the peak power of around 75 kilowatt and the talk is the same what the go what that engine is having

Because we are having a spec heet it is hello yes sir what do you mean by unladen like you have mentioned in the reability section unladen is you know this currently is the unladen weight okay okay which there is no load no driver sitting inside okay curve weight

In short yes un let curve weight okay gross vle weight is that when it is with the full load it is the driver is inside right okay so when we get this power rating is a half of the power rating which we get now we get clear with the power and

Definitely it is a pmsm motor because the requirement is very clear and for this uh here we have to go with the voltage what kind of voltage we have to use so weuse the 384 volt here because you know the motor is Big the power requirement is Big the better the power

The better the voltage you know higher the voltage lower the current the I square or losses will be very less which means heating of the wire heating of the batteries will not be there so we go with the high voltage system to calculate with the battery what kind of

Battery we have to use because you know I’m taking uh you know uh 40 kilometer per hour I’m here what I do the twist is that I I calculate this thing as a 100 kilometer but for this particular thing it is a duty cycle but I’m taking it as

Okay 100 kilomet uh it has to run so basically for a vehicle we go with that part but it you know sync in the I can say how it sync so for Reference Lab Test it is my formula to go with the 1 kilowatt we use one ton so 1 kilowatt of

Of uh you know the motor it is we we calculate the one one kilowatt 1,000 kg it’s a very simple example you can get it from the IRA so lab reference we have there from there if you go with the Ia there are you know 750 Kow of motor

There is 1200 watt of motor and the load the 8 n people are sitting there so almost we take it as a one turn for 1 kilowatt and the energy consumption in the you know uh the reference we take a 70 wat hour per kilom for one turn so

For the one turn with the 40 km speed it should be almost 70 to 80 it varies but this is something which you take as a reference and it also depend on the vehicle Dynamics and lot of other factors also but to ensure with the battery capacity you know rough you know

Whatever I’m talking about here in the calculation part there is always in difference in the Practical Parts when you go with the Practical when you make the when you do the all the things there is always a error of margin but this gives us a better reference how we have to go

With that uh calculations so if if I talking about the weight 15 t t gross weight 30 uh uh 30 turn why have return the 23 uh just wait uh it’s uh 30 t uh it’s a 23 turn basically it’s not a 30 I guess so here I this this is uh so

It’s a 15 weight 15 turn and uh the lifting capacity is not 15 T it’s something I think around 11 11 T so that makes 23 T so okay if you take it to 30 also so you have to multiply 70 into 30 because I mentioned here that we take 70

Wat hour per one turn so it’s a basically 70 wat hour you have to multiply with the 23 I we take it 30 but for the 40 kilm per hour we are just taking currently cons you know assuming it is not any kind of crane we are just

Consuming assuming it as a vehicle electric vehicle so for that we are doing calculation so for 100 kilom running at 40 kilm we have to just multiply the value which we get it from here to the kilometer there we get at the kilowatt hour of the battery

Consumption and taking 20% DOD in that it is a 193 kilo kilowatt it’s not K it’s a kilowatt hour which required the battery for running this vehicle for 3 hours with the 40 km speed to 100 kilomet but that that is not something in the crane because here we need the

Duty cycle so what does basically this means and the battery which we use in this vehicle is the same is 150 wat kilow battery which we used so the calculation this formula which I mentioned here it was almost the same because I have taken a lot of margin of

Error here I have taken the 40 you know 43 kilowatt hour more because there are a lot of things which we it is basically rough formula which we are using but there are better it depends on the type of gear type of you know wheel wheel base lot of

Things are inside which which you have to go with a very uh at every single step you have to calculate but these are the some kind of you know uh check your uh the assumtion to check your uh motor what kind of motor you’re using so

This is a photo when we start working on this is the during the launch he is the owner of the company so when it was launched but there are a lot of challenges in this SC so uh uh in this scane when we made this scane uh this is

The motor was accurate the power rating was accurate which we made the battery was also there now if you know that in this crane there is 5 ton of weight which is installed here it is in the form of iron dust and also iron but here

In in the petrol one here you can see this is the petrol one uh sorry diesel one I’m again saying here it is engine which we have removed so in this vehicle here the company uses the fire T of the iron dust and iron you know the

Load basically to ensure that when it lifts the 15 ton of weight or 10 sorry it’s not 15 it’s uh you know 10 11 10 of weight it will get balanced otherwi what happen that if it lifts the weight there is no weight here it will get you know

Down from this side so they always keep the weight here in this battery what now we have the issue here that the uh cost analysis now we calculate that okay if we are using 150 Kow hour of battery in this scen it cost only 25 to 30 lakh

Rupees or for the battery so how it can be achievable because this crane which is available in the market with 18 20 lakh rupees it cost 40 lakh rupees and there is no sense to buy this motor crane then we keep you know brainstorm and we come into the come to conclusion

That we will use the lead acid batteries here we use exide batteries which is giving us same power with the but not a normal batteries that battery with a good grade so the batteries you know for the graphine batteries what the issue is that they are having very they’re very

Bulky they’re having very big weight lithium is not having that weight so that weight you know blessing in the disguise basically that weight we use as a counter weight here so that it provides the power but also provide the counter otherwise we have to use a 30

You know 5 ton of iron to ensure the management weight balancing of the crane so that you know battery gives us the counter weight also and make the price half of the you know from the lithium so this is the thing which we have then this I don’t know what is the

Cost of this but that that makes a very big difference in this whole Crane and here also we see the challenges such as that the vehicle is not running at 30 kilm per hour speed like basically 40 I’m talking about but it is 25 kilm per

Hour which is which they permit to the screen and we see that uh there is heating issue again and again then we work on the compressor side to ensure is all hydraulic system because all the things are running from the engine we couple it with the motor and you know

Most amazing thing what an Innovative thing we develop in this scen is that only a single motor is running the vehicle running this boom also so here is the one compressor which uh hydraulic or not compressor hydraulic which run this crane boom so one single motor is

Doing all this thing so this is the in Innovation this is the tech which is developed in the total in India and this is how we have to solve the problem so this Al the one case study which we work on and this is successfully launched by Shiri nitin gkar G last year

And this is something product which we are very proud of and we are we have learned a lot of things from this we are implementing something bigger in the future also but from you know oldest vintage car which we have done in 19 16 that we make to electric and that is

Running you know very smoothly and fine uh today also and the another biggest 30,000 you know 400 kg was that vehicle weight and this is a 30,000 kg we started from that and we are you know continuously going but this is something the achievable we have got so the

Approach is very clear you have to just go with the the assessment you have to go with the planning the power rating the particular motor the particular uh the choice of uh the frame and you have to just go with logical what we have to exactly client need from

Us otherwise what happen that we become the alen musk we become the you know some kind of scientist we start saying okay we can do this we can do that no see what client need see how much this vle can go up to see how kind of things

We can use the cost benefits the cost analysis to the user and how we can this thing scalable this is not and you know we are having in the retr fitment there is 18% tax for the new there is only 5% tax tax so one challenge is there and

For the retr fitment people see this industry as a it’s a scrap kind of Market but no it’s a 70 billion dollar of Market it’s a very big Market but only challenge is that we not working very clearly and but we are we are we are getting results but yes if

People come with this solutions with this approach they can definitely help so if you want to connect with me you can just scan the code it’s a LinkedIn code you can connect with here and close my screen and come to the question answer round so uh scan this if you want to connect

I’m closing in my screen and coming to the screen hello hello yeah yeah sir sir can I get your mail ID or number like uh I can’t provide you my number but I can definitely give a reply on LinkedIn so if you are having the link here you

Can scan this code I will get you’re not able to scan it just search so I will just uh write in here my name I can I will share my email in the chat box so I hope this uh session is very helpful because you know uh this

Subject is not something which I can tell you in a you know one hour or two hour it take it took me around 3 to four years to just learn I can say 10% of what the E is but it’s a very big subject it’s a very vast subject and

Everybody has to you know study by their own I can just give you the highlights what this engine is and let’s sorry to interrupt yeah I have a question here yeah sure please so I can see that there are multiple things involved when you decide

Something say a r retrofit to be done to a vehicle a two wheeler or a four-wheeler so uh from a student point of view so who is planning to do something on a retrofitting what would you suggest it’s like a more of a basic where I would see this calculation part

Once you understand the requirement from the customer and you’re going to see what is the ROI on say converting this retro so later that part there are multiple Technologies multiple people involved like your mechanical your uh uh electrical electronics programming U simulation part so how exactly you’re going to handle all these

Like multiple teams uh there I’m not able to understand like if a student would like to get into a retr where exactly he can focus uh look uh uh Abdullah the thing is that retr fitment is not something which is you know a student for a student it’s basically

EV it is only it is you know I want to work in a car company okay which car company you want to work I want to work on a you know in a Hyundai or in a maruti it is the same retr fitment is basically electric vicker you are you

Are not making something you know totally different it’s the same EV same only chases there so for a student if you want to go into the AV industry for a retr fitment I will I will suggest you know if you want to make your own startup I would suggest don’t do this is

A very this is a very challenging industry don’t do either you don’t have a lot of money in your pocket and no investor will give you the money right I’m I’m you know yes sorry for the interruption I just wanted to let you know that session

Is really nice I mean okay I’m glad to see that uh even after 2 hours the students are so interested and they are taking the interest in your session so it was just a compliment I thought that if I’m here because I’m not from the technical background I’m the HR but

Still even I was thinking what are these things and even I was enjoying that so it’s a really nice I hope the students are also enjoying the session yeah I I hope you all everybody I’m not good in explaining I try my best because you know really lovely session

And I just came to check and I was like y students are still her and participating even definitely is I think it is something which make everybody more you know relatable coming coming back to Abdullah to your question uh you know getting back to you know e in any

Company either it’s two wheer three-wheeler the architecture is always same I will just you know just give me I will share you uh a later if you connect me on the mail basically it is it is something not for the start look yes yes sir sir one question speaking in Hindi myish week

Like Tech FOC bind dream eind already service power same uh motor arure retrofitting in is same you can work on that being as a student if I have to go open my startup don’t do this industry is not something you know chenging two retrofitting but I told you

College project is something which you can make when you come at the customer so it’s a better to work with the companies like doru is a very good platform from you can have placements and all from there you can you can connect with the industry and make

Yourself you know uh harad of that industry okay thank you thank you thank you I have a a small question if if I can sure sure definitely so first of all thank you Jad thank you lavisha and everyone at DIY Guru and I’m already student with you so

My question is about the crane the F-150 crane you have you have been like retrofitting so I know that the the the like the compress the the compressor needs like the motor the the diesel motor to be all all all the time on to to feed it like to to feed the

Hydraulics and stuff so how did you tackle this like how how did you deal with this do you like uh like plug in the the crane all the time to electricity or do do you have like a something to deal with this sure thank you thank you David for the

Beautiful question so basically what we do is that you know when I said that one motor is running you know giving a traction to the uh whole whole vehicle it is moving the vehle and it also working lifting the boom also the compressor hydraulic is basically there

So uh there is one uh reducer there when you plug that reducer it get disconnected from the tires like with the power train and it gives power to the boom and yes the motor has to run continuously but there one challenge which came with us is that to run the

Motor at the exact RPM because when you lift the load you need the you know higher RPM it’s same with the engine also so for that we have to uh integrate uh one electronic device there which send the load and as per that it increase the RPM of the motor and which

Helps in lifting the uh weight thank you very much thank you thank you uh there is I can see four question from rafik that is retrofitting being neglected by government yes definitely it is neglected because you know it is something uh industry which I can say uh

Very good industry but currently it is neglected but people know government are thinking on this because look rafik nobody has done till now has shown the result to the government and everybody is saying so reduce a tax reduce this reduce this and why there is no subsidy for the

Retrofitting because nobody has ever done the but now the good part is that we had a meeting with Delhi government and they are providing subsidy on the Retro fitment even Hyderabad is also providing Telangana people government is coming with this scheme why doesn’t government standardize retr for all the available

Motor this is really this question you know even we had put it in front of the ministry also but you know proposal you know is rting a profitable business definitely is a profitable business but it is the business in which you become the default OEM so a business profit to standardize the things

To work on your whole system to make it profitable because profitable or uh yes no sense any other body I hope I give question answer to the every question and sir I think I think right simple question ,000 8,000 R does it make a sense yes sir

Right if you’re having a better off in the market why you go with the retroit I told you in the starting you have to choose the market very wisely like we had opportunity from groups choose your market and customer very wisely okay Sir Manish uh I think Lish uh there’s no other person or uh sir I just texted you something uh let me just can please pardon the question uh can you please come back uh modification that you make to but how you to to make it t branding

Where people feel it yes definitely is you know it is definitely like modification that you make to vles but a major one how do you plan to look you know branding uh you know trustworthy it always become with your work and with your choice of the components and brand

Is not buil in a one day and if if I if I talk about that uh we went to you know that place there we find the bearing you know the the experience we have sharing and we spend our almost 30 40,000 rupees you know on a single person so that is

How you make your brand how you make your people trustworthy because you know that is our fault we have not taken care of these things in the starting in the table so component first of all the standard of quality of the material the quality of the component and the quality of the

Approach even the process you have to Define in the starting and then when your you know work is in the market then your action speaks and then your brand becomes some kind of you know trustworthy and people start you know if if if tple is getting repeated order

Every month I think we are on that way yeah thank you sir thank you for the session thank you uh all right I think all the questions are clear if you have any question feel free to approach me I guess um it’s been quite late time for Mr zad also yeah my

Back is hurting now yes even our team is working till now so I guess uh we should wrap up the session as of now we’ll be definitely planning this once again and it was a lovely session like students are not ready to leave it’s getting too interesting thank you thank

You so much I hope I just give you my you know whatever the best I can yeah I shared the LinkedIn IDs of you of me and of DIY Guru they can directly connect to us you can connect with me asish andad Khan to him and you can directly inbox

Us sure you can you can send the pbd uh leish sham G is having I have shared him the PPD I will share him the revised version and if anybody need you can send accordingly please contact uh the tauru team for the pp it is you know sure sure

Jaad thank you for your time jaad I think this this was one of the most interactive session we have ever had thank you thank you I hope everyone liked it thank you so guys uh uh for update we are on next Sunday we are organizing one more session like this

I’ll share the update for the topics and all uh uh thank you guys uh and we are we are start soon starting a batch uh for placement oriented course specialization course uh if anyone required for such kind of training uh do let us know all the information contact

Related details already been shared in the chat box you guys can feel free to reach us thank you Javad thank you everyone Fork you every good night thank you laisha thank you for your time good night everyone thank you thank you have a good night everyone by bye bye

Good night good night good night thank you thank you bye that

Revamp Your Ride: Turn Your Gas Guzzler into an Electric Dream Machine! ⚡
Ready to ditch the pump and join the EV revolution? But don’t want to break the bank on a brand new car? Then retrofitting your existing 4-wheeler might be the perfect solution!

In this video, we dive deep into the exciting world of electric vehicle (EV) conversions. We’ll show you exactly how to transform your conventional car into a clean, quiet, and eco-friendly electric machine.

What you’ll learn:

The pros and cons of EV retrofitting.
Key considerations before taking the plunge.
Step-by-step guide to the conversion process, including:
Assessing your vehicle
Choosing the right conversion kit
Installation and wiring
Batteries and charging
Testing and registration
Expert tips and tricks to ensure a smooth and successful conversion.
Real-world examples of converted vehicles in action.
The latest regulations and resources for EV retrofitting in your area.