The transition from internal combustion engine (ICE) vehicles to electric vehicles (EVs) is a critical step toward sustainable transportation. This study investigates the conversion of a patrol car into an electric vehicle using a 5 kW direct current (DC) motor coupled directly to the gearbox. A 100 Ah battery was used as the primary energy source, with a 70Amps alternator initially considered for charging. Mechanical integration focuses on motor-to-gearbox alignment, torque transmission, and vibration isolation, while electrical design emphasizes battery management, motor control, and auxiliary power systems. Performance modeling indicates that a 5 kW motor provides limited acceleration and range, making the system suitable primarily for lightweight vehicles and short-distance commuting. Analysis reveals that the alternator, producing less than 1 kW, is insufficient for traction battery charging and introduces energy inefficiencies. Instead, a dedicated charger and DC–DC converter are recommended for reliable operation. The findings highlight the feasibility and limitations of low-power EV conversions, offering insights for educational projects, prototype development, and short-range applications.
Jankam et al. (Tue,) studied this question.