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Analysis of Technical Capabilities, Methodology and Test Results of a Light-Commercial Vehicle Conversion to Battery Electric Powertrain

Author

Listed:
  • Piotr Bielaczyc

    (BOSMAL Automotive Research & Development Institute Ltd., 43-300 Bielsko-Biala, Poland)

  • Rafal Sala

    (BOSMAL Automotive Research & Development Institute Ltd., 43-300 Bielsko-Biala, Poland)

  • Tomasz Meinicke

    (BOSMAL Automotive Research & Development Institute Ltd., 43-300 Bielsko-Biala, Poland)

Abstract

This paper describes a holistic development and testing approach for a battery electric vehicle (BEV) prototype based on a self-supporting body platform originating from a vehicle powered by an internal combustion engine. The topic was investigated in relation to the question of whether conversion of existing vehicle platforms is a viable approach in comparison to designing a new vehicle ab initio. The scope of work consisted of the development stage, followed by laboratory and on-road testing to verify the vehicle’s performance and driveability. The vehicle functionality targeted commercial daily use on urban routes. Based on the assumed technical requirements, the vehicle architecture was designed and components specified that included various sub-systems: electric motor powertrain, electronic control unit (ECU), high-voltage battery pack with battery management system (BMS), charging system, high and low voltage wiring harness and electrically driven auxiliary systems. Electric sub-systems were integrated into the existing vehicle on-board controller area network (CAN) bus by means of enhanced algorithms. The test methodology of the prototype electric vehicle included the vehicle range and energy consumption measurement using the EU legislative test cycle. Laboratory testing was performed at different ambient temperatures and for various characteristics of the kinetic energy recovery system. Functional and driveability testing was performed on the road, also including an assessment of overall vehicle durability. Based on the results of testing, it was determined that the final design adopted fulfilled the pre-defined criteria; benchmarking against competing solutions revealed favorable ratings in certain aspects.

Suggested Citation

  • Piotr Bielaczyc & Rafal Sala & Tomasz Meinicke, 2021. "Analysis of Technical Capabilities, Methodology and Test Results of a Light-Commercial Vehicle Conversion to Battery Electric Powertrain," Energies, MDPI, vol. 14(4), pages 1-18, February.
    • Handle: RePEc:gam:jeners:v:14:y:2021:i:4:p:1119-:d:502617
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    References listed on IDEAS

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    1. Jarosław Wątróbski & Krzysztof Małecki & Kinga Kijewska & Stanisław Iwan & Artur Karczmarczyk & Russell G. Thompson, 2017. "Multi-Criteria Analysis of Electric Vans for City Logistics," Sustainability, MDPI, vol. 9(8), pages 1-34, August.
    2. Falcão, Eduardo Aparecido Moreira & Teixeira, Ana Carolina Rodrigues & Sodré, José Ricardo, 2017. "Analysis of CO2 emissions and techno-economic feasibility of an electric commercial vehicle," Applied Energy, Elsevier, vol. 193(C), pages 297-307.
    3. Li, Zhenhe & Khajepour, Amir & Song, Jinchun, 2019. "A comprehensive review of the key technologies for pure electric vehicles," Energy, Elsevier, vol. 182(C), pages 824-839.
    4. Shahid Hussain & Mohamed A. Ahmed & Ki-Beom Lee & Young-Chon Kim, 2020. "Fuzzy Logic Weight Based Charging Scheme for Optimal Distribution of Charging Power among Electric Vehicles in a Parking Lot," Energies, MDPI, vol. 13(12), pages 1-27, June.
    5. Juan C. González Palencia & Van Tuan Nguyen & Mikiya Araki & Seiichi Shiga, 2020. "The Role of Powertrain Electrification in Achieving Deep Decarbonization in Road Freight Transport," Energies, MDPI, vol. 13(10), pages 1-24, May.
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    1. Louback, Eduardo & Biswas, Atriya & Machado, Fabricio & Emadi, Ali, 2024. "A review of the design process of energy management systems for dual-motor battery electric vehicles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 193(C).

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