The global environmental pollution issue and global warming caused by internal
combustion engines (ICE) have prompted automotive manufacturers to pioneer the
development of emission-free or pure electric vehicles. The Indian government
declared that all ICE cars will be replaced by electric vehicles by 2030. Thus,
after 2030, ICE vehicle scrapping will be prevented by retrofitting.
Transforming traditional cars into electric vehicles in Indian markets reduces
emissions and enhances sustainability. This work aims to transform the Maruti
Suzuki Zen petrol car into a fully electric vehicle while keeping its pristine
transmission system with an onboard charging system. During the fieldwork, all
unnecessary components of the ICE are removed to transform it into an electric
vehicle. The E Zen’s maximum speed, gradeability, and driving range on both
level and sloping roads were also examined. The performance was assessed using a
72 V, 144 Ah lithium-ion battery pack and an AC induction motor with a peak
output of 15 kW. The vehicle’s dynamic performance was evaluated, and the
findings indicate that the vehicle’s maximum speed, grading capacity, and
driving range are 60 kmph, 12.5%, and 100 km, respectively. The weight of the E
Zen gains a mere 6%, which is deemed acceptable according to the ARAI standard
for retrofitted vehicles in India. The modified vehicle has a 73.41% lower
operational cost than the gasoline-powered car. This technique stops global
warming and shields the environment from damaging vehicle emissions.
The results were promising, and the proposed system functioned adequately for its
intended purpose. This work offers exceptionally viable outcomes by achieving
efficiency in both economic and environmental aspects.