This project presents the design, development, and implementation of a retrofit electric conversion kit for the iconic TVS XL moped. The aim is to enable a seamless and cost-effective transition from internal combustion to electric power, contributing to the rise of sustainable mobility—especially in rural and urban settings where two-wheelers are essential.
The retrofit kit is engineered to replace the ICE drivetrain with a BLDC motor and lithium-ion battery pack, requiring minimal modifications to the original vehicle frame. The system offers:
- High torque output
- Optimized weight-to-power ratio
- Simplified charging and power management
- Up to 50 km range per charge
It serves as a scalable solution for low-cost EV conversion with real-world performance validation using theoretical modeling, simulation, and hardware integration.
| Component | Description |
|---|---|
| Battery | 48V, 24Ah Li-ion |
| Charger | 48V/4.5A on-board charger |
| Motor | BLDC hub motor |
| Motor Controller | Smart controller with speed, torque, and regenerative braking logic |
| Converter | Dual buck DC-DC (48V-24V, 24V-12V) |
| Frame Mods | Minimal, to accommodate battery + motor |
The project includes:
- Dynamic analysis of forces (rolling, gradient, aerodynamic)
- Motor sizing and torque simulation
- Battery and charger spec optimization
- Acceleration modeling with MATLAB