Petrol to Electric Kubota Conversion Kit

Performance Capability:

The function of a UTV is to perform in extremely cold temperatures, rough terrain, and wet conditions due to snowfalls. To ensure functionality was maintained analysis was performed in these areas. The batteries and motor were chosen based on their ability to perform in cold weather as well as effective waterproofing has been applied to ensure off-road capabilities are maintained.

The vehicle will be operating with temperatures reaching -40 ℃ in the Yukon and will affect the vehicle’s start-up and efficiency (Travel Yukon, n.d.). A gasoline engine functions through the combustion of fuel to start up which can be kept warm through the release of heat while operating. Yet, they can take time to start up due to sub zero temperatures freezing up the engine oil if the vehicle is not being kept inside overnight. Similarly, the Curtis AC motor selected can be treated the same as it was with the petrol engine in cold conditions. Heat will be generated with the motor and distributed throughout multiple components in the system as it operates.

Affordability:

A main aspect of the project is the ability for anyone to replicate it and as such affordability must be considered. The cost of the electric motor and the rest of the required materials for the conversion are easily recuperated in cost savings from purchasing fuel.

The original petrol engine required 20 L and currently fuel prices are as high as $1.77/L resulting in $34.50 to fill up the UTV completely. Based on a fuel efficiency of 0.3222 L/km, the fuel cost $0.57/km. The batteries of the electric motor require a full charge time of 20 hours on a standard outlet. Given the current electricity prices of $0.187 per kWh it costs only $2.69 to fully charge the batteries. With a continued range of 20 km the cost drops to $0.13 per km.

Overall, the ten-year lifetime cost of the conversion is approximately $16,000 (including charging, maintenance, and the conversion costs). This is approximately $4000 less expensive than the lifetime cost of a new electric UTV and nearly one third the lifetime cost of a petrol UTV.

A large aspect of this project is the community context in which the project takes place. As mentioned previously, the surging fuel prices in Northern communities has greatly increased the cost of living for people. Alongside the conversion additional educational resources were created for anyone to replicate our conversion. Additionally, in late April, the team will fly to the KLRS. The purpose of this visit is to better understand how the product fits within the day-to-day operation of the station and within the context of broader Northern communities. We will also visit the local school to discuss the project with the goal of sparking an interest in STEM in the local youth. In addition, to the in-person discussions, the project documentation and supplementary educational resources will be shared to guide others in converting their gas-powered vehicles to electric. As the purpose of the project is to meet the needs of remote communities, all of the acceptance criteria was rooted in these considerations.

• Community Engagement: The project was created on the idea of supporting communities and it is important that this was kept at the top of mind while working on the project. Throughout the project it is evident that every decision was made while keeping the community context in mind. At the end of April, the team will be traveling to the Yukon to directly engage with the community and attend the Renewables in Remote Communities 2022 Conference. (Pembina Institute, 2021)
• Sustainability: The goal of the design was to provide a sustainable solution for rising petrol prices for Northern Indigenous communities. As mentioned above the design proved to effectively provide a sustainable solution as it positively impacts the environmental, economical, and social aspects of sustainability.

• Affordability: The project had to remain affordable to ensure it was not ineffective. Overall, the initial budget was surpassed due to unforeseen circumstances, however over the long term the project still proved to be an effective cost savings method. Originally the UTV would cost $34.50 to fill up on petrol and with the conversion the cost to fully recharge is now $2.69. The ten-year lifetime cost of the conversion is approximately $16,000 which is approximately $4000 less than buying a new electric UTV and nearly one third the cost of the original petrol engine.
• Replicability: A large aspect of the project was ensuring that anyone could replicate the design. To effectively account for this, support documents were created that outline materials required as well as drawings are provided. Throughout the design process we ensured that every part could be ordered online or purchased in local stores.

• Technical Specifications: The initial criteria of the project were to meet the manufacturer’s technical specifications for hauling capacity and speed. The project was able to effectively surpass the manufacturer’s specifications in both categories. Both the power capacity and horsepower increase after the conversion. As mentioned above the power capacity increased by 12% resulting in an increase of hauling capacity and the horsepower increased by 39% resulting in a higher top speed.
• Performance Capabilities: The capabilities of the UTV had to be maintained to ensure functionality was not lost. The project effectively met all performance capabilities that were originally present. Both the batteries and motor were chosen based on their ability to perform in cold weather to ensure top performance in the frigid northern temperatures. The off-road capabilities of the UTV are provided through its mechanical systems. To maintain performance these systems were preserved, and effective waterproofing was completed to ensure off-roading capabilities were maintained.

The dimensions of the motor were analyzed in solid works to confirm the fit of the electric motor with the transmission. As shown below a key shaft and flange were required however, the selected motor was confirmed to be a perfect fit for the transmission.

The second major component of analysis was the batteries. Batteries provide a wide range of choice such as performance enhancement, reliability, safety, affordability, etc. The battery selection for the Kubota UTV was assessed between two types which were Lead Acid or Lithium based deep-cycle batteries. Relating back to the design being affordable and easily replicable four GC12 150AH Deep Cycle batteries were chosen. To keep the batteries within their operational range, the team identified “Canadian Polar Pads” as the most effective means of heat transfer. The pads operate similarly to an electric blanket, only requiring 120V, and have a sticky adhesive that allows them to be attached to a wide variety of surfaces. Moreover, the polar pads are capable of heating components from -30 °C to a temperature of +20 °C and are widely used and available in the arctic regions.

Affordability was a key consideration when determining if the project was feasible. If the design proved to be too expensive the conversion would be rendered impractical. Despite the design costing more than originally speculated the conversion still proved to be the most cost effective option when comparing a ten year lifecycle cost. The lifecycle conversion cost was approximately one third the cost of the lifecycle cost of the original petrol engine and nearly $4000 less than purchasing a new electric UTV.

Overall, the design proved to be feasible. Considerations were made throughout the design process to ensure the project was able to be easily replicated. The project also proved to remain the most affordable option when compared to other similar options.