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PluginIndia Electric Vehicles

Suzuki Swift Dzire Electric Car Conversion with Gears

17/4/2021

52 Comments

 
By Atul Gopal
We had an opportunity to visit Nothway Motorsports to check out their new electric car conversion kit. In this blog, we talk about the ideas implemented in this certified kit, after experiencing the car and speaking to the founder Mr Hemank Dhabade
Video : ​Suzuki Swift Dzire Electric Car Conversion

Hemank Dabhade is an electric moto-head. Spent his younger days in drag racing. And drag was what attracted him to EV's, The thrill of the Newton meters rush even at 0 rpm! He has been doing a great job of bringing back e2os from the dead by kiting them with new battery packs. But e2os have never really been mainstream. At peak production, they were doing a few hundred a year. That's what Maruti Suzuki makes in a few hours. So Hemank has set his eyes on what mainstream buyers would like to buy. 

The Nexon EV electric car has proved that familiarity sells in India. The magic sauce is to take an existing best seller and electrify it. So Hemank chose Maruti Suzuki's Swift Dzire. The Dzire has two distinct advantages over the Nexon - it's lighter and it's got better aerodynamics. And both these characteristics also help deliver on range. Hemank claims that the Dzire EV that he has come up with has a power consumption of about 85 Wh/km. With a 25 kWh battery this would mean a range of 25,000/85, approximately 300 km. The Wh/km does not include AC, so realistic range can go down to about 250 km. To put this in a Nexon perspective, the average Nexon gobbles up about 200 Wh/km, and with a 30 kWh battery - that means a range of 150 km.

For a kitted car to handle well, you also need to understand suspensions. A car's springs and shockers are designed for a certain weight distribution. If you change the weight or it's distribution, then the handling will change. Imagine a Nano EV project where the motor and battery gets fitted on the front wheel. (The Nano is a rear engine, rear wheel drive.) The smaller front wheels and the relatively less stiff front suspension will now be in trouble. So you have to ensure that your converted car weight matches that of the original. (Government norms for conversion allow you a 10% deviation.) And you also need to ensure that the weight distribution between front and rear remains as close to the original as possible. 
Picture
Picture
Hemank starts an EV conversion project by creating a 3D map of the vehicle - with special attention to fastener locations. This forms the framework in which he has to fit the electronics and the electricals. The EV Dzire weighs in at 950 kg. The petrol Dzire weighs around 915 kg and the diesel one at 965  kg. So the weight is in tolerance limits. Unlike CNG kits, EV kits dont eat up the boot space. There are only 3 things that go out of the car - the engine, the fuel tank and the exhaust pipe. These are replaced by the motor and two battery modules. The battery modules have the same form factor as the equipment that they are replacing. This split battery helps in evening out the load between front and rear axles, to match the load split of the ICE cars. 

The existing Swift Dzire vehicle electronics is made to believe that it's actually the engine that is running. This is done by some clever engine mapping. You look at sensor output at different torque rpm combinations and modify the EV sensor outputs to match ICE outputs. This means that you don’t need to rebuild the Car OS. On the odometer, the motor rpm is displayed in the same space as the engine rpm. (System on is indicated by 1000 rpm.) The SOC has been calibrated to be shown on the fuel gauge. 

The radiator is put to good use for battery cooling. There is also a chiller for the coolant after the radiator. I don't think that ver 1 has got battery heating - but it should not be too difficult a feature to add. Some loss of precision is there. Hemank plans to add a bluetooth fed dashboard mounted gizmo to show stuff like actual SoC, regen and battery health. There is no change to the chassis. Which means that you can get the kitting done by a good local mechanic.

There are some advantages of retaining a mechanical gear box. Range is the most important one. The motor runs between speeds of 500 to 4000 rpm. So to remain in the range sweet spot of speed, you use the 5th gear on the highway. Clutch is there. With a low coefficient of drag, you can expect a lower Wh/km vis-a-vis the Nexon at highway speeds. Hemank uses a custom made motor, with the rotor on the outside. This helps deliver better torque, as the electromagnetic forces are away from the shaft. Motor is rated at 60 kW peak and 30 kW continuous power. Top speed is a humongous 160 kmph. Thanks to the high starting torque of motors, you can run this car as an automatic. You can start in the third gear and stay there for all your city driving. 

DC Charging and regular CCS charger is standard. The charger is located in the fuel tank lid location. Would have liked a storage area for the cable which can be accessed easily. It will take an Apple kind of company to actually realize that some thinking has to go in to making the charging experience more pleasurable. The cable is not really featherweight. And it tends to get twisted into Gordian knots in storage. Some thinking is required. I like the Chetak's solution of putting it in a special slot in the front dicky. It's a ground up scooter - and so it's easy to execute such comforts. Did not get a good look at the underside, but some work required there. Especially in the exhaust pipe area. We did hit a speed breaker in our small trip. Regen is there. But regen fine tuning is an art - and would only comment on that once I get to actually drive the car.

Maruti should adopt the Northway model - and sell it as a sub brand like the way AMG does with Mercedes. AMG stands for performance - and so does Northway. Speaking for myself,  I would have preferred that a kit be developed for the Baleno. It\s a more contemporary car with great looks and finishes. Did you know that Suzuki buys Balenos from India for export to Japan! 

EV kits are still not popular. One reason could be reliability - warranty void etc. The other could be capital cost. But EV kits make for great commercial and economic sense. They give a clean second life to vehicles. Government should mandate electrification of mechanically sound cars after the 15 year life gets over. The acid test for electrification would be with fleet owners. How much are they ready to spend. If the kit is priced around 4 lakh, Northway has a killer. but looks very likely that the figure will be closer to 6 lakh. Fingers crossed!
52 Comments
Tarun
17/4/2021 11:24:53 pm

Have to say a lot. But for now . incredible job boss. I have never thought the specs you mentioned for this car was ever possible. Really impressed. Intrigued by hardwork you put in it. I hope it soon tesla upcoming 4680 cells will come to india on cheap rate & will work wonders with your electric system & transmission.

Still incredible job. Thanks for it. Wish you success for upcoming time .

Reply
Dinesh link
9/7/2021 01:15:05 pm

Car

Reply
RAJEEVE KAUSHIK
18/4/2021 07:50:18 am

I'm very interested in EVs.
Please inform if you can help in converting WagonR.

Reply
Vijay kumbhani
12/8/2021 04:39:24 pm

I have interested

Reply
Uday
18/4/2021 03:49:16 pm

Great job.

Is there a way to convert my celereo to electric car ?

Reply
Stanley Varghese
18/4/2021 06:57:01 pm

What are the charges for i20 or Maruti Swift

Reply
Patodkar subhash
31/3/2022 11:22:50 am

Cost of Swift convertion

Reply
Ajay Rayabarapu
23/4/2021 09:29:27 pm

Dear sir,
I have a matiz . Can I get it converted into Electric? What would be the cost? If I want it in 80/90 kmph and with range 250+?

Reply
Kalpesh
24/4/2021 06:14:30 pm

I am interested to convert my car Renault Kwid into an electric car. I want to know the cost of it. My contact number is 9662474677.

Reply
Shankar Ganesh Prasad
25/4/2021 10:02:02 pm

Namaste 🙏. I've got an Ertiga. Petrol . I wish to You convert it to an E' Ertiga. If you could please give me an idea about Cost .
Regards
Ganesh Prasad.S #9886991666

Reply
Manjunath Wali link
29/7/2021 08:10:10 am

8317430822 call me

Reply
Ajay Patel
27/4/2021 08:51:25 am

I want to buy car from you. How?

Please msg or call. 9265773701

Reply
James Smith
1/5/2021 12:10:58 pm

this was vey ideal blog for taxi. on the off chance that you need to see more , check this site <a href="https://latestbikesandcars.com/">Latest bicycles and cars</a>

Reply
ankit link
6/5/2021 03:41:58 pm

nice information got swift car in ev fulfill needs of customrs good job team work excellent

Reply
Sumit s Sharma
9/5/2021 06:30:21 pm

Plz send number

Reply
Yogender Kumar Kadian
10/5/2021 02:31:22 pm

Hemank ji plz send ur contact no.
I am interested to convert my scorpio engine into ur ev kit. Plz contact me on
9050181899,9081500009

Reply
Kamlesh Kardate
23/5/2021 09:49:05 am

I am interested to convert my car Maruti Ritz into an electric car. I want to know the cost of it. My contact number is 9644558855.

Reply
Shubham Bawankar
27/5/2021 12:39:40 pm

Sir I want to work with you. I am electriele engineng . I wanted to be the part of future change. Sir please cl or text mi..
7768861393

Reply
Kailash Tawri
28/5/2021 01:06:19 pm

Pl. Call back as I am interested to convert ny swift dezire - VDI CAT INTI EV. PL. CALL 9824850862

Reply
V Gadgil
1/6/2021 10:41:34 am

Wonderful job done.
I would be interested in converting my 2006 petrol tata indica.
Please let me now if it's possible.
If not, what would be the options.
Awaiting your valuable response.
Thank you.

Reply
Santosh Palaskar
3/6/2021 05:36:33 pm

Hi, how much expence / cost is required to make it electrical.

Reply
David Jensen link
17/6/2021 06:43:41 pm

Wow, very nice blog. I have written a blog with more information about Sell your Car with Car Dealerships trade or private sale

https://vitacars.business.blog/2021/01/06/sell-your-car-with-car-dealership-trade-or-private-sale/

Reply
Deepak link
19/6/2021 12:29:19 pm

I am interested to open a showroom for that faculty in Indore how do I contact you please tell me

Reply
Viswanathan Hariharan
25/6/2021 02:32:24 pm

I'm interested in buying a car can you please call me at9841005647

Reply
Om Nagarkar
27/6/2021 09:45:13 pm

I would like to work as franchise

Reply
Diwan Sharma link
29/6/2021 04:21:39 pm

We are interested joint venture with your new startup business,
I have prime location land 6000 Sqyd . Delhi NCR Main Road
Please contact us 9810828696

Reply
Raghu
6/7/2021 12:10:47 pm

Kindly share the details pls 9740091074

Reply
Vinod Phalke
7/7/2021 09:47:34 am

I want to purchase this car, Definately..

Reply
sudhir
7/7/2021 11:32:37 am

I impressed its mileage and it's max speed 250to300km is more than nexon and we have to go 160km is best speed only we have to go for second hand 1lac car and give hime 3to4lacs saving of money instead of wasting mahindra e20 tata tigor electric and nexon 13lacs car so compared to 3 it's cheap also upcoming car stormr3 cost is 4lacs and 200km range so this is best

Reply
Selvadurai Muthukani
12/7/2021 06:53:14 am

Very Nice research. I am an Electrical Engineer from Madurai, Tamilnadu. I would like to explore any business opportunity with your guidance. Please respond

Reply
Nikesh Jain
19/7/2021 10:29:13 pm

Needed conversion cost of my i10 automatic 2009

Reply
Shantanu Kumar Mohanta.
27/7/2021 07:08:05 am

Sir which kit r u use in this car is it made by u or any other ev car kit u use in this car plz give ur contact details For business.

Reply
Dr A K Biswas
29/7/2021 03:57:40 pm

Can it possible in Wagon R 2010 model. How much cost I have to pay in my Wagon R 2010 model to convert to electric system with gear ? please let me know to my email- drakb7@yahoo.co.in then I will send my car to you from Kolkata.

Reply
Sreedharan Menon
30/7/2021 01:10:36 pm

Hi...I am interested in hybrid conversion of my petrol car elantra 2015 model, to hybrid electric pack with kit..this is a automatic car and would love to hear about it...Sreedharan Menon, from Mumbai

Reply
Prashanth
1/8/2021 04:06:10 pm

I need a contact number for this converetion. Pls contact me on 8122197858

Reply
Chaitanya Chugh
7/8/2021 12:11:53 am

Sir , I am from New Delhi and I am really interested in your EV conversion for my Swift Dzire ( 2016 model ) . Please let me know when will your company be available in Delhi for the same.
My contact detail is : chaitanyachugh01@gmail.com

Reply
Rohit sindhu
8/8/2021 01:18:02 pm

Want to convert my swift desire diesel to ev , what is the cost involved ?

My number 9911448580

Reply
Manoj
8/8/2021 07:52:06 pm

I want to convert my Honda Brio to electric but what is guarantee that it will work as is after converting to EV ? And what if it did not work well ?what will happen to petrol engine and other spare parts?

Reply
Pravin
9/8/2021 06:21:28 pm

I have wagon r 1.0 l vxi model 2019 and wanted to convert into electric vehicle.
May it be possible
If, yes. What's to do
Please inform me on my email or 7992422668.
Thanks.

Reply
devanandan link
23/8/2021 12:56:30 pm

hi morning this is devanand from chennai i can join with u jv to chennai
thankyou
devanandan
9841061234

Reply
Subhas
26/8/2021 11:01:48 pm

Sir wonderful job done by u.It will change complete indian motor scenario. Hats upto u

Reply
Haranath
1/9/2021 10:25:40 pm

Interested in converting my vehicle. Please do send your contact details. Regards.

Reply
Shivam Gupta
2/10/2021 08:05:46 pm

9450379666

Reply
Pinal
5/10/2021 10:11:34 pm

I want to convert my car into EV. It's my dream for years. Please replay me soon. 9427312392

Reply
Naresh
14/10/2021 11:53:18 am

Please contact me on 9167692592 Hemankji. I have a Ford Aspire. I am interested to convert it into an EV.

Reply
Sourabh patil
25/10/2021 09:38:33 am

I have petrol version Celerio. I need to convert into Ev. Can you please share your contact details.
So that I will reach to you and discuss further details.

Reply
Srinivas
21/11/2021 04:17:37 pm

Want to buy electric car

Reply
Ajimsha Albac
24/2/2022 07:04:31 am

Is it possible to convert Ford figo titanium 2017 model petrol engine?

Reply
Bijithdharan
3/4/2022 01:17:05 pm

Pls send me the contact details to contact

Reply
Shivam Thareja Advocate link
16/4/2022 02:35:06 am

Planning to convert my Innova into an EV

Reply
Bhavesh shah
30/8/2022 12:31:14 pm

I am Bhavesh Shah I am interested to convert my SX4 diesel engine please send detail

Reply
raj
15/10/2022 05:05:02 pm

can you please let me know the convertion price swift vdi with 250km range

Reply

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