Design and Development of Motor Controller and Electronic Differential System for Electric Vehicle Conversion

National efforts to improve air quality in the country have revitalized the interest in the development of electric vehicle technology that can be sustained for years to come. Battery-powered vehicles not only offer a diminished carbon impact on our environment but also provide an economical alternative. Considering the high prices of commercially available electric vehicles, our project is aimed at converting an already available combustion engine model into a BEV (Battery Electric Vehicle). Our project addresses all design considerations involved in this conversion and comprises of the hardware implementation as well. The project kicks off from the removal of the internal combustion engine and related assembly from a commercial vehicle (Suzuki Mehran). It then goes on to cover the design and development of EV controller, practicability of commonly used differentials, and development of EDS, if needed. After this, our efforts tend to direct towards installation of EV components and integration of accessory systems. All of this ends in implementing, testing and optimizing the designed system on the designated vehicle.