EMotorWerks Modular Mechanical Conversion System
The main feature of the EMotorWerks design is modularity and simplicity of the conversion process.
EMotorWerks has designed a patent-pending mechanical system to hold all the EV components and attach them to the donor vehicle. The system is adaptable with minor modifications to many types of passenger vehicles. The initial application of the system will be tailored to the mid-market vehicles (BMW / Audi / Mercedes). The BMW 3-series solution is already developed
All parts are pre-manufactured and pre-assembled so that complex technology is enclosed in “bolt-on” modules. Installation of such modules does not require skills or experience beyond those of a typical automotive shop mechanic.
In addition, modular design allows for a variety of customizations. For example: different battery packs can be installed in the vehicle based on the customer’s demands of price and performance; simple modifications to components can adapt the conversion kit to new car models. Moreover, customers will have an option to upgrade their EV by simply replacing one or more components.
The mechanical part of the EV conversion kit consists of the following main modules: battery enclosures (with batteries), battery mounting frame, the electric motor mounting frame and the electric motor. Other parts (not all covered here) include various cables, cable mountings, controller, charging unit, electronic control unit, power steering pump, vacuum pump, etc.
Battery cell enclosures designed in a modular way can be easily installed and replaced. For example, our BMW 3-series conversion solution has five different battery enclosures (boxes): two boxes located under the hood (in front of and on top of the motor), one box in the trunk in place of the spare tire, and two boxes underneath the car in place of the fuel tank. Each battery enclosure consists of a number of standard form factor LiFePo4 cells connected in series. With the appropriate cell distribution and enclosure configuration, it is possible to achieve the optimal 50/50 weight distribution. Low placement of the enclosures inside the vehicle improves the car stability.