Meenakshi College of Engineering

Mechanical department 4TH year

 CONVERSION OF PETROL ENGINE TO E – VEHICLE

WITH TRANSMISSION GEARS
by
A.R.ABDUL RAHAMAN
. S. ABDUL SAMATH
 . A.AFSHAL MUTHALIFF
. S. JAWAHAR
GUIDED BY
Mr. ANAND
ASSOCIATE PROFESSOR /MECH
Introduction

 Today , one of the Most important problem facing by our country is

the petrol , diesel Insufficiency and increase of its price value.
 So rather than implementing new ideas of producing a fully New E-
vehicle, we can also use old petrol vehicles by converting that
into a E-vehicle.
 In India there are mostly petrol vehicles used , so we cannot easily
throw that and suddenly change to a new E-bike .
 We can use the same petrol vehicle without petrol as fuel.
 Problem definition

 Government has announced that , by 2030 India will be 100% E-vehicled

nation .
 Most of the automobile industry stopped their manufacturing process of petrol
vehicles , so their is a enormous employment opportunities are fired.
 The condition of petrol vehicle consumers is Concern.
 It is very difficult for a middle class person to buy a new E-bike suddenly after
buying a petrol vehicle .
in order to overcome the drawback ,Conversion of petrol engine to geared E-
Engine is developed
Basics of petrol engine
 Conversion concept

Normal systematic mechanism Replacement for Camshaft sprocket

 Working
 The main concept of this project is not to use petrol for running a petrol
vehicle , so we have to connect the motor in the place of camshaft sprocket.
 So , initially we have to cut the piston and it’s connecting rod for placement of
the motor .
 Then the motor shaft is connected with a small sprocket .
 The motor sprocket is then coupled with the gear transmission sprocket .
 Now , with the help of motor driving kit ,we can connect the motor with
accelerator for running it.
Mechanism

 Normal petrol engine uses pistons reciprocating motion

as rotory motion with the help of crank shaft For the
movement of vehicle.
 In our developed E-Engine project, the motors rotating
motion is directly transmitted to the gear box for the
movement of the vehicle.
Components and methodology
• In the place of engine head, the piston will be in reciprocating
motion,as we are removing the piston and connecting rod we can
place the motor in the place of that.

Components Materials

Motor 48v 750v bldc

Motor controller Regulator module 36v

Battery Lithium ion 48v NMC

Sprocket and chain Metal

COMPONENTS OF EXISTING VEHICLE
SPECIFICATIONS OF MOTOR AND
CONTROLLER
SPECIFICATIONS OF BATTERY
TYPES AND COMPARISION BETWEEN
LI – ION BATTERIES
COST OF MOTOR AND KIT
COMPONENTS
COST FOR BATTERY OF
E – VEHICLE
 Approximate mileage estimation
At 40kms with 100kg load it can run ulto 140 kms with fully charged 30Ah battery
 Theoretical calculation
Formula for Calculating range should be as follows:
Battery Nominal Voltage x Battery Capacity (Amp-Hours) / 20 Watt-Hours/Mile.
Example: 48V-12Ah Battery – would have 48x12 = 576 Watt-Hours of Energy / 20 WH/Mile = 28.8 Miles of range (at
20 MPH, motor only).
So for 48v 60ah battery would have 48x30=1440 watt-hours of energy/20 WH/Mile=72 Miles of range (at 20 MPH,
motor only).
 Practical testing
Speed of the motor without load - 3000 rpm
Speed of the vehicle with 100kg load-40 kmph
Mileage of the vehicle for 30 ah battery full drain -140 km
Speed of the vehicle with 100 kg load - 50 kmph
Mileage of the vehicle for 30ah battery full drain -115.5 km
Advantages

 We can easily turn a petrol engine into E-vehicle.

 We can also make speed transmission by gears.
 The cost for making this arrangement is very less then
buying a New E-vehicle
 Improved efficiency .
 Great lifecycle and less maintenance.
Working videos
Removal of engine oil
REMOVAL OF AIR FILTER
REMOVAL OF CARBURETOR
REMOVAL OF ENGINE HEAD BORE
CASING
REMOVAL OF ENGINE CASING FOR
REMOVING PISTON
AFTER REMOVAL OF ENGINE
OUTER CASING
MAKING OF MOTOR GEAR BY MACHINING
(MILLING) A 33 TOOTH GEAR SPROCKET
BEFORE

AFTER
ASSEMBLY OF E-VEHICLE
Conclusion

 The Conversion of petrol engine to geared E-Engine is simple

and also very needed change in our today’s nation ,
Implementation of this project will lead to increase more
number of E-Engines in our country , thus by implementing this
project more middle class petrol vehicle using consumers get a
great benefit.
 The petroL engine – E engine is a future Device which will help
the mankind to Achieve 100% E-nation before 2030 without
affecting the poor and middle class people.
Thank you
Failure can never overtake me If my Determination to succeed is strong enough