Mihir Vardhan has been fascinated by instruments because the age of three.
The 20-year-old was launched to the world of engineering by his mother and father, and obtained his first toolbox from his father when he was six years previous. Since then, he’s been tinkering round with objects together with his screwdriver and constructing issues like robots, LED panels, and 3D printers.
“My father would purchase me and my brother little lights, bulbs, and batteries. He would train us how one can wire them up. Each birthday, I’d get some type of instrument. I began constructing my assortment on the age of six and it continues until at the moment. My whole room become a workshop,” he tells The Higher India.
When he was in Class 8, Mihir launched his YouTube channel referred to as ‘Making with Mihir’. He wished to speak his love for engineering via this channel.
Whereas he began from small tasks like constructing a torch, at the moment, his works have grown into one thing larger. Take, for instance, the petrol automobile that he transformed into an electrical automobile.
His newest video, titled ‘Easiest EV Conversion beneath $3000 – Convert Your Automotive in 3 Days!’, has grabbed fairly just a few eyeballs.
Changing a automobile to electrical in three days
The concept for this was born nearly a decade in the past. Mihir credit his household good friend James Abraham for instilling the thought in his head.
“James’ uncle is an engineer and used to show me about electronics. He’s a ‘inexperienced man’ and runs a photo voltaic firm. After I was in Class 5, he advised me that we have to convert a petroleum automobile to an electrical one. He used to say that we should always purchase a small automobile like a Maruti 800 and convert it. At the moment, I simply laughed it off. However he stored reminding me of this challenge yearly,” he says.
Mihir is at the moment pursuing electrical engineering on the College of Illinois and is in his third 12 months. When he returned house to Gurugram for a brief journey in September 2021, James reminded him of the challenge but once more. This time, Mihir took it critically and determined to go forward with it.
He determined to transform his grandfather’s 12-year-old Hyundai Santro.
“The Santro was simply mendacity in our storage and I believed, ‘Why don’t we take the engine out and make it a totally electrical automobile?’. It’s an exquisite automobile, solely the engine is just a little drained. I went on the web and looked for movies of individuals changing vehicles. However as an alternative of replicating what others had carried out, I made a decision to make some tweaks,” says Mihir.
He says that the three most vital issues in the case of conversion are selecting a motor, a controller, and a battery.
Whereas the wheels had been set in movement in September, they got here to fruition in January 2022, when Mihir returned to India for a brief journey.
“I went on the Indiamart web site and reached out to sellers of things I wanted. Slowly, the items of the puzzle began falling into place. As my journey to India was a really brief one in January, I needed to execute this in a brief interval. I really like tight timelines and the problem,” laughs Mihir.
Making the conversion easier and cheaper
As soon as he reached India in January, he began ordering the motor, controller, battery, and converter to interchange the automobile battery. It took nearly 10 days for this stuff to reach. He was left with simply three days earlier than he flew again.
Mihir was clear about two issues with respect to the conversion — maintaining it easy and low cost.
“I wished to maintain the method so simple as attainable, and use as a lot of the automobile as I might. I additionally wished to minimise the welding and machining, and devise a course of which might be carried out within the basement of your constructing with out utilizing fancy instruments,” he says.
In actual fact, he did the conversion utilizing a primary socket set, a flooring jack, and two bricks.
Often, in such conversions, the whole engine is eliminated and changed by a motor. However Mihir determined to take away solely half the engine.
“When the whole engine is eliminated, you could add two extra motors to energy the facility steering pump and AC compressor. You additionally then should give you mounting brackets and add a number of wires. It’s time-consuming, tough, and costly. I made a decision to depart half the engine in, and mount the motor on the remaining a part of the engine,” says Mihir.
Whereas this may compromise efficiency and effectivity, it’s sufficient for metropolis driving, says Mihir. The benefit is which you can energy the wheels of the automobile, the facility steering pump, and the AC compressor. This manner, he has additionally saved about Rs 1.5 lakh, he says.
Modifications made within the automobile
Mihir began by taking out the engine. He eliminated the engine head and pistons to cut back the engine’s weight and retained the engine block. He then mounted the 6 kW Brushless DC motor on prime of this engine block utilizing an L-shaped motor block. He linked this motor to a 350A Kelly Controller.
He positioned the 72V 100Ah Lithium Ferrophosphate (LFP) battery within the trunk. He has positioned the charging wire the place one would normally put petrol.
Since braking could be a problem, and he wished energy braking, he added an electrical brake booster vacuum pump. He additionally added a 72-12V DC-DC convertor to cost the battery that powers the locks, lights, and energy home windows.
Mihir spent Rs 2.4 lakh on this conversion. The automobile runs at a prime pace of 60 km/hour and has a variety of 80 km.
He additionally says that the price of working this automobile is lower than Rs 1/km, whereas a petroleum automobile prices Rs 8-10/km, together with upkeep.
“Though a automobile’s efficiency could be higher with a bigger motor and battery, that is adequate for metropolis driving. Additionally it is a great use of an end-of-life automobile just like the one I used. As an alternative of throwing it out, and including to the carbon emissions, we will reuse it like this. In most end-of-life vehicles, it’s solely the engine that doesn’t perform properly, resulting in elevated emissions. By changing to an electrical automobile, you save on these emissions,” says Mihir.
As per a report by the Centre for Science and Atmosphere (CSE), India could have greater than two crore end-of-life autos by 2025. The report says that these autos will trigger enormous air pollution and environmental injury.
Such conversions is usually a good use of those autos, for us and the atmosphere.
“I need to get individuals occupied with changing their vehicles to electrical. There are such a lot of sources obtainable on-line. Simply communicate to sellers on Indiamart and your native mechanics. They’ll be capable of present a good suggestion of the totally different choices obtainable,” he says.
“I need to get individuals occupied with changing their vehicles to electrical. There are such a lot of sources obtainable on-line. Simply communicate to sellers on Indiamart, and communicate to your native mechanics. They’ll be capable of present a good suggestion of the totally different choices obtainable,” he says.
Mihir additionally took the assistance of his native mechanic Ustad, who was with him all through the method. He hopes to encourage extra individuals to take up engineering and use their data for good. Through the peak of the pandemic, two of his tasks vastly benefited the general public.
He says he printed greater than 1,200 face shields for docs utilizing a 3D printer at house. He additionally created UVC (Ultraviolet C) machines that might sanitise and disinfect.
“I created two disinfection chambers first, one huge and one small. As soon as individuals noticed them, orders began to pour in. I named it the Terminator Mega and bought one to the PMO’s workplace, and 6 to the Military. I additionally created a robotic referred to as Terminator Turbo that may sanitise a complete room,” he says.
He’s now specializing in tasks associated to sustainability and hopes to start out a sustainable enterprise in India after ending his engineering.
In 2018, he solved the issue of a excessive electrical value at an orphanage close to his home. He designed and managed the set up of a 19.5 kW photo voltaic plant on the orphanage, which now has decreased their prices to an ideal extent.
“I need to work in direction of sensible, reasonably priced, and accessible options for sustainability,” says Mihir.
‘India could have over 2 crore end-of-life autos by 2025: CSE Report’ Revealed on 28 September, 2020 Courtesy Autocar skilled
Edited by Divya Sethu, Pictures courtesy Mihir Vardhan