An Automotive Design, Challenge Based Learning Activity for Undergraduate Engineering Students: An ICE Vehicle Conversion into EV

A Challenge based Learning (CBL) activity, with the participation of an industry partner, regarding automotive design for undergraduate engineering students is presented. During an academic semester, senior students in an specialization course became familiar with technical aspects regarding electric vehicles (EV) and learned about battery pack sizing and motor sizing as well. Students worked on a challenging case study to convert a VW Type 1 sedan with an internal combustion engine (ICE) into an EV. The work done by the students involved real-data, simulations, cost analysis, 3D scanning, multiple CAD design iterations, and manufacturing processes. The achieved outcomes of the case were: an improved dynamic behavior and more sym-metrical weight distribution compared with the original vehicle, as well as a comparable power and energy delivery were also achieved at a lower cost compared with commercial conversion solutions. These results are evidence of the skills developed by the students as the CBL activity was developed and shows a promising project option for engineering students. It is observed how challenging students through a motivating situation that demands their intellectual curiosity, seeking to solve problems of global interest, and focusing on an application in their area of expertise, contributes to their professional development. This is an option for future final capstone projects in engineering.