[stuntfreak]

Hello My Fellow Team BHPians! It's Good to be back!

In my quest to make the Most Sophisticated EV Conversion after converting many vehicles in the past, I decided to start off with a brand new Swift Dzire (Since it's one of the most easy to relate to sort of vehicle).

Last Year Feb I purchased a Swift Dzire Petrol Vxi and drove it straight to my little place of joy and happiness (Workshop) to create something amazing.

Sure I do own a few OEM Electric Vehicles and ICE Converted EV, but my aim was something different. I wanted to solve the common man's problem. How to build an Electric vehicle, (In my case a conversion kit, since I am no complete Vehicle Specialist), that has amazing performance, a great range, amazingly simple to use yet sophisticated, and is not too expensive to build.

In my quest to solve this issue, I ended up hiring many people, to develop everything in house since as over time I figured out, almost 90% of the most important things needed in order to build an EV, aren't available in India. Please bear in mind that this has always been more of a hobby and passion for me. And I do intend to help others like me to create their own DIY EVs.

We ended up developing the entire EV Powertrain ourselves. The specs of the Swift Dzire EV are as follows:

1. Motor - 15 KW, Peak 35 KW
Max Torque: 170 Nm at Motor Shaft, 842 Nm. at Wheels.
2. Battery Pack - We did develop 3 options for this particular vehicle. 13 KWh, 15 KWh, 18 KWh. Location: Fuel Tank and Tunnel Area. Entension in the Exhaust Area in case of the 18 KWh.
3. Transmission: 5 Speed Manual with lightened Flywheel and Usable Reverse
4. Weight Distribution: Same as OE with a max error of 5%
5. Total weight addition to the vehicle - 3 kg. Only. (Original Vehicle weight before conversion: 947KG. After conversion: 950 Kg)
6. VCU Compatibility - End to End. Complete Integration with all CAN Functions. Instrument Cluster, Throttle Peddle, Power Steering, All Controls, ABS, Airbags, EBD, etc.. Everthing is Fully Functional
7. Water Sealing: IP67
8. Vehicle Top Speed Capability: 160 Kmph
9. Gradability: 34%
10. Towing Capacity: 3 Tonnes Vehicle with free rolling along with vehicle self and occupant weight.

For the Air Conditioning, I am using a separate BLDC Motor that is actuated by the original Clutch switch. The Radiator Fan turns on when necessary (Battery Cooling, Power Electronics cooling, AC Chilling Etc.)

For Charging, we have installed a CCS 2 Port in the fuel nozzle insertion area which can be accessed by opening the fill cap. The Vehicle is Capable of Charging from 0 to 100% on a 15A Socket in 8 hours. We are working on Fast Charging, haven't got there yet, but will soon have that established too.

The Instrument Cluster is re configured as follows:
Tachometer Now shows Motor RPM
Fuel Guage now shows SOC
Engine Check light now shows Motor Drive Fault
Temperature guage now shows Battery Temperature
When the Car's Ignition is Switched off the Speedo Meter Shows the SOC (between 0-100) thus indicating percentage of Charge for Easy and Precise Visibility. We are constantly upgrading the software to integrate more functions.

Everything in the car works absolutely Fine, and I am very very happy we finally got things right this time.

On a full charge, the Vehicle returns a range of 250 kms when driven carefully, but unlike some OEM EVs, Careful Does not mean SLOW.. Ohh noo. I also do own a Nexon EV. And I know what a pain it is to drive at 40-50 kmph on the highways just to reach your destination. My Swift on the other hand returns excellent range at high speeds, thanks to our multispeed Transmission. I have been trying to explain this to many many people for nothing less that 15 years, that a multispeed / CVT Transmission will unlock the true potential of Electric Vehicles.

Most people might say, Why have a Gearbox on an EV? Well, Why NOT?

My Swift Dzire EV:
A. Produces Fantastic Torque thanks to the First Gear
B. Is usable on a daily basis in 2nd and 3rd
C. Returns Excellent Range on a single charge at Highway Speeds while still providing Lots of Torque in 4th and 5th gear.

So there you have it. Having a Multi speed Transmission, on any EV Traction motor that does under 15000 RPM is always beneficial despite the slight efficiency loss that it may have to bear.

So In short, the Electric Swift turned out to be an amazing car. I also did get the necessary Govt Permissions to Legally Drive my Vehicle on road

Do Check out the Video of this beautiful vehicle in action

https://youtu.be/3sv6f4smmhg

Enjoy Folks.

See ya Soon!

Teaser: In one of my work in progress images, you shall also be able to see another setup that we have made for the Swift - High Performance EV.. That would produce 1200NM. Wheel Torque.. Will be my next post..

[sandeepmohan]

Fantastic work my friend.

It look like packaging all the mechanical bits can be done with help from CAD drawings, the experience you already have with conversions, etc. The bigger challenge being energy storage. Looking at the amount batteries that need to be coupled together, cooling them, ensuring they withstand the daily grind of driving under varying conditions (High heat, good roads, bad roads, dust, etc) and how they cope in the event of a collision.

How much gains are to expected under brake energy regeneration?

[Shresth_EV]

Great job!

250km from merely 18kWh sounds too good given how other EVs at this battery size barely manage 150km (I’m looking at you tigor and verito)

This is almost Nexon EV level range from battery half the size.

I never imagined that a using a gearbox would be so much better. Even the Taycan used a 2-speed unit but 5?

I’m now seriously inclined to think manufacturers should add gearboxes. Efficiency loss seems to be well balanced out with range improvement.

How much is the estimated cost for such a conversion?

[rdst_1]

Fantastic job mate.
There is a growing trend in the west where people are converting their classic cars into EVs. I hope that with decreasing costs of components, we should soon be able to do the same in India. Would love to able to electrify my Fiat Palio if and when it's engine goes bust.
This is what I love about Electric vehicles. With a lot less moving parts, DIY like yours turn out into a much more solid product than in an ICE setup. Was just watching a Jay Leno video in which the Ford CEO was unveiling the Mustang Mach-E and they talked about not needing the gearbox. Any comments on that.
Also, if you don't mind sharing, which chemistry and company cells are you using for the battery pack. And same for BMS if possible to share.

[ant_vas]

This is Fantastic! Kudos to you for attempting something like this and getting a result which outshines come of the commercially available EV's in India right now!

Being a Swift Dzire AMT owner, i need to ask this, can this setup work with AMT transmission? will there be any performance challenges with AMT?

[stuntfreak]

Originally Posted by ant_vas

This is Fantastic! Kudos to you for attempting something like this and getting a result which outshines come of the commercially available EV's in India right now!

Being a Swift Dzire AMT owner, i need to ask this, can this setup work with AMT transmission? will there be any performance challenges with AMT?

Thanks for your compliment. Certainly can implement on AMT As well. Our VCU is smart enough to talk to your TCU for the new shift logic.

Originally Posted by rdst_1

Fantastic job mate.
There is a growing trend in the west where people are converting their classic cars into EVs. I hope that with decreasing costs of components, we should soon be able to do the same in India. Would love to able to electrify my Fiat Palio if and when it's engine goes bust.
This is what I love about Electric vehicles. With a lot less moving parts, DIY like yours turn out into a much more solid product than in an ICE setup. Was just watching a Jay Leno video in which the Ford CEO was unveiling the Mustang Mach-E and they talked about not needing the gearbox. Any comments on that.
Also, if you don't mind sharing, which chemistry and company cells are you using for the battery pack. And same for BMS if possible to share.

During my years of search online, I could not find the needful components in India to work on projects like this. Hence We ended up developing everything inhouse. But others like myself can now buy from me instead of reinventing the wheel.

We've used LFP Cells - Camelion. BMS Is built inhouse.

Most EVs abroad use extremely high RPM Motors thus negating the need of a Gearbox in order to achieve speeds. Imagine you have the transmission stuck in say 1st gear, and the motor is capable of 15000 rpm. You basically get the torque you need due to the step down ratio, and the top speed due to the high revving motor unlike an ICE.

What my argument is that: Just because a motor can spin really really fast, doesnt necessarily mean its efficient while doing that!

This is exactly where adding a gearbox helps. This is the same reason the Nexon EV Returns a range close to 300 Kms on a single charge if driven at 50 kmph, on a light foot, where as with the same type of throttle input, the car will be extremely inefficient say at 100 kmph where it will return just 150 kms on a single charge. There may be other factors at play here, like aerodynamics and stuff. But consider the efficiency drop in a Nexon Petrol at 50 kmph vs 100 kmph, and consider it in a Nexon EV at 50 and at 100.

Adding a multi speed transmission helps you drive the vehicle with the motor in its sweet spot.

If you can reduce the power consumption with respect to work done, you can downsize the system's design, weight, and cost.

Something to think over, isnt it?

Originally Posted by Shresth_EV

Great job!

250km from merely 18kWh sounds too good given how other EVs at this battery size barely manage 150km (I’m looking at you tigor and verito)

This is almost Nexon EV level range from battery half the size.

I never imagined that a using a gearbox would be so much better. Even the Taycan used a 2-speed unit but 5?

I’m now seriously inclined to think manufacturers should add gearboxes. Efficiency loss seems to be well balanced out with range improvement.

How much is the estimated cost for such a conversion?

A good range is actually achieved by a combination of: Lightweight, Good Power and Torque, Minimized Consumption, and enhancing mechanical efficiency as per speeds with a Multi speed transmission. The main reason why the Gearbox is so efficient is because of the programming and design of the motor and controller. We have optimized it to be used on a Multi speed transmission. The Motor speed range is also equivalent to ICE (7500 RPM Max) thus making the whole scenario a well fit one. The Gearbox also does not have lubration issues as it will run in the designed speed range.

More than a 5 speed, ideally, a CVT is best suited.

Originally Posted by sandeepmohan

Fantastic work my friend.

It look like packaging all the mechanical bits can be done with help from CAD drawings, the experience you already have with conversions, etc. The bigger challenge being energy storage. Looking at the amount batteries that need to be coupled together, cooling them, ensuring they withstand the daily grind of driving under varying conditions (High heat, good roads, bad roads, dust, etc) and how they cope in the event of a collision.

How much gains are to expected under brake energy regeneration?

Thanks a lot buddy. The Battery pack is designed with a reinforced Aluminium enclosure and is packaged well within the Empty pockets of the BIW which ensures no portion protudes outward. The pack is IP 67 and Liquid cooled. It is monitored by our BMS and VCU.

Cheers buddy.

[rdst_1]

Originally Posted by stuntfreak

Most EVs abroad use extremely high RPM Motors thus negating the need of a Gearbox in order to achieve speeds. Imagine you have the transmission stuck in say 1st gear, and the motor is capable of 15000 rpm. You basically get the torque you need due to the step down ratio, and the top speed due to the high revving motor unlike an ICE.

What my argument is that: Just because a motor can spin really really fast, doesnt necessarily mean its efficient while doing that!

I don't have any real world knowledge about this, but I can link you to the jay Leno video where they very briefly talk about it. I understand that what you are doing is completely different from what they are doing. It's just for discussion and knowledge. They talk about the gearbox at 16:20 and they made a comment about how DC motor is more efficient at higher RPM than lower RPM.

https://youtu.be/VrjPD8uBmxQ?t=976

The reason I ask this is because apart from electrifying my current vehicle, I would be really interested in getting some small electric vehicle (most likely like an ATV) designed and built from you for my farm in the near future.

[swarnava.ch]

Dear Stuntfreak, Kudos to your efforts, will definitely follow your posts further to keep myself updated on some of your other projects.
Two points which stand out:
- Fit and Finish of the final product, amazing, doesn’t look like reworked at all.
- Its very interesting to see that you got permission to drive on road.
- In house BMS and other components - hats off, these require quite a lot of time, effort and dedication to develop.

I am a ex-EV owner and a supporter of EVs in general and have a a few questions for you hope you won’t mind sharing your views on the same.

1. Will you be able to commercialize this as say Kits that owners can get retrofitted and enjoy their car longer with valid paperwork ?

2. I have always had the opinion that PHEVs are a better value proposition. If I get a pure EV range of say about 100 kms which will take care of regular in city commute (office) and I still have the regular 1.5 lit ICE for the occasional highway drive. I feel this combination can be amazing to win over customers if decently prized. Would love to hear your views on this ? Can your kits achieve something like this ?

[S2K]

This is fantastic and hugely motivating too!
I see your location is Pune. I, being based in Mumbai, would like to be part of your current and next projects. Is there any way I can be?

[Digital Vampire]

Huge congratulations Stuntfreak and your team behind this - This is probably the best EV Conversion I've come across in India, period!

You folks truly have the potential to become the "EV West" of India and beyond

If I may ask, by any chance, are you sourcing the motor from India OR is it imported?
Just curious since I've been babying this dream of converting my ageing 4WD Hyundai Tucson to EV almost forever but the import costs and hassles were a total turnoff!
Your projects are sort of rekindling the hope within!

[pgsagar]

Stuntfreak, that's excellent work. Look so OEM. Anyone who is not much into cars would think this is assembly-line built. Is a car so made RTO/Insurance compliant? And, why did you buy a Nexon EV? I mean you have the wherewithal to make an EV yourself.

Can an ICE torque converter be converted into EV retaining the TC gearbox? Does RTO approve of it and issue an RC?

[sajaijayan]

Absolutely fantastic effort. Wishing you all the success and hope EV conversions also take off in a great way. With efforts such as yours, I am sure this will happen in the very near future.

A design suited to Indian conditions and requirements is the need of the hour in India and kudos to you in enabling that.

[eyeman]

Congratulations stuntfreak. This looks amazing. I am a great fan of the EV revolution, but in India it looks like EVs are going to be overpriced for some time. An excellent solution ill be what you have done. Would you mind sharing the approximate cost? Do you have any plans for going commercial? Larger volumes will bring the cost down surely? I have a 13 year old SX4 as well as an 8 year old Accord. I would love to convert these if it can be done with legal approval.

[shibu]

Brilliant work and near OEM finish.

Have you changed the drive shafts to take in 850nm or are they OEM?

[HornNotOkPlease]

You have undertaken a mammoth job altogether and the specs are just awesome, I couldn’t make it from pics but have you designed a battery pack structure which bolts on or how are you fitting the battery clusters to the body? I am curious in that case how are you maintaining the battery temperature? The heat profile of different battery clustered would degrade the clusters differently and it would eventually be a tough task to balance them.

Considering how much OEMs spend on r&d in developing the BMS, it a commendable effort if you have them developed in-house