ElectroRick: Converting the Classic Auto-rickshaw into an Electric Marvel

Project Overview:
Led a team of 4 to retrofit a conventional autorickshaw to an electric vehicle (EV) in a 9-month project. Collaborated with cross-functional teams of mechanics, welders, suppliers, and auto-garage to complete the project. Designed, modeled in 3D, procured, and converted the auto-rickshaw to run on batteries, achieving a top speed of 35 km/h and a range of 50 km on a full charge. Learned valuable lessons in system integration and design tradeoffs.

Project Description:
Before going hands-on, we created a mathematical model of the system to determine the motor specification, speed, and torque requirements. This served as the foundation for our project.

Responsibilities:
Led a team of 4 in the design, modeling, procurement, and conversion of the auto-rickshaw to an EV.
Calculated and procured the appropriate motor and its control circuit based on the mathematical model.
Procured the battery pack (5 batteries in a series total of 60V, 42 AH) that can take the load and provide the required range.
Bought a used vehicle, gutted it, and retrofitted it with the axle, accelerator, and most of the electronics.
Redesigned the chassis of the rickshaw to accommodate the batteries, motor, and axle using Fusion 360.
Removed all the IC components from the conventional auto-rickshaw, namely the engine, CNG gas tank, gearbox, and air filter.
Connected all the electronic components using copper wires and bench-tested them with the power of the 5 batteries.
Fabricated new parts on the chassis of the rickshaw using existing components to mount them along with the differential axle and new components.
Mounted the electric components on the rickshaw and connected the battery to the controller and the controller to the motor.
Conducted road testing of the rickshaw on a nearby road, achieving a top speed of 35 km/hr.

Outcome:
Successfully converted a conventional auto-rickshaw to an EV that can run on batteries, achieving a top speed of 35 km/h and a range of 50 km on a full charge, with an easily swappable battery bank and a cost of conversion within an affordable range. Learned valuable skills and lessons in system integration, design tradeoffs, and project management.