Document Type : Research articles
Authors
1
Mechanical engineering department, Faculty of Engineering, Pharos University in Alexandria, Alexandria, Egypt Department of Mechanical Power Engineering, Faculty of Engineering, Tanta University, Tanta, Egypt
2
Mechanical department, Faculty of engineering, Pharos University in Alexandria (PUA), Alexandria, Egypt
3
Mechanical engineering department, Faculty of Engineering, Pharos University in Alexandria, Alexandria, Egypt
4
Mechanical engineering department, Faculty of Engineering, Pharos University in Alexandria, Alexandria, Egypt – Email: 202100703@pua.edu.eg
5
Mechanical designers, Tanta, Egypt, Phone: 01006564959, 01114313971, Email: haztal313@gmail.com
6
Electronics and Communications Engineering, Faculty of Engineering, Tanta University
Abstract
This study develops a replicable framework for converting a 1998 Opel Vectra into a fully electric vehicle (EV), combining mechanical retrofitting with dynamic performance optimization. The methodology systematically replaces internal combustion engine (ICE) components with a 96V AC brushless DC motor (15 kW peak) and 60-kWh Li-ion battery pack, achieving a total mass of 1,670 kg. Power demand analysis shows a 54% increase to 14.24 kW at 120 km/h compared to an 800 kg baseline, with aerodynamic drag contributing 83% of total resistance. Urban driving cycles yield 205 km range (293 Wh/km) at 30.2 km/h average speed, while a 15% tire pressure reduction is shown to degrade range by 18%. Structural reinforcements to the chassis and suspension accommodate the battery load, validated through finite element analysis (FEA) in Autodesk Inventor. The proposed design reduces conversion costs by 30% relative to commercial kits while maintaining OEM safety standards. These results demonstrate a balanced approach to EV retrofitting, prioritizing energy efficiency, structural integrity, and economic feasibility for sustainable urban mobility solutions.
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