Electric Vehicle Conversions
Private cars and transport vehicles are one of the nation’s largest sources of carbon emissions making finding low or non-polluting alternatives a major priority over the next decade.
There are a multitude of alternative personal transport options from bikes through to trains, but very few alternatives to support individuals and businesses transport goods and services.
Since 2007 CERES has been involved pioneering the design and conversion of, VicRoads compliant, electric vehicles (EVs), including a project with Swinburne TAFE School of Engineering which will results in to the establishment of Australia’s first accredited electric vehicle conversion and maintenance courses.
CERES specialises in the retrofit of existing vehicles to electric drive, in contrast to newly manufactured EVs, in order to produce EVs that eliminate the additional carbon emissions that result from the manufacture of fleets of new electric vehicles.
Using an existing car frame also has the added benefit that the car already complies with current Australian safety standards.
CERES is now embarking on the design and conversion of one of Australia’s most popular large delivery vans, the Mercedes Sprinter, to an electric motor that will be able to travel a minimum of 100 kilometres per charge and carry 880 kilograms of cargo.
The outcome will be to providing a model of a positive transport solution for business that addresses the dual challenges of climate change and peak oil.

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Specifications: |
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Vehicle |
Mercedes Sprinter Van, LWB, Mid roof |
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Range |
100-120 kms per charge |
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Budget |
$105,000 (original petrol vehicle - $51,000 new) |
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Conversion Timeline |
18 months |
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Motor Capacity |
70-90kW (approx) |
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Battery Type |
Lithium Ion |
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GVM |
3550 kgs |
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Kerb Weight |
1960 kgs |
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Battery Pack Size |
55 kwh ($35,000) |
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Voltage, Amp Hour Rating, Charging Methods |
288 volt, 180 amp hour |
What are Electric Vehicles?
Electric Vehicles (EVs) are cars that use batteries to power a non-polluting electric motor. The batteries in an EV can be charged by drawing electricity from the mains power supply, or from renewable energy sources such as solar and wind power.
Regardless of the source of electricity, electric motors are probably the most efficient systems for propelling cars making EVs both financially and environmental less costly than petrol powered cars.
EVs are also faster, quieter, more energy efficient and more mechanically reliable than petrol engine cars. They also hold the road better, respond instantly and smoothly to the acceleration pedal and have a better safety record.
Carbon emissions from cars, trucks and other forms of transport make up between 9 -12% of Australia’s carbon pollution emissions. At the same time oil, used to power most transport, is reaching the point at which half the world’s reserves have been used up. The second half is lower quality, the extraction process highly damaging to the surrounding environment and expensive to buy.
Cars that use traditional fuels have almost reached their limit as far as increasing efficiency and reducing carbon emissions are concerned. Although it is possible to keep improving engines with more sophisticated computers and pollution control mechanisms, the results will be neither fast nor significant enough to achieve useful carbon reduction targets.
Advances in electric vehicles has meant that EVs can now travel up to 350 kilometres on a single charge, reach speeds of 120 kph and the batteries only need to be replaced after 1000 cycles (discharge and recharge events), or approximately every seven years under typical usage patterns.
New lithium batteries for EVs are relatively expensive, but this is only due to economies of scale. The price is expected to drop significantly as lithium batteries become more widely used in the rapidly expanding hybrid vehicle market. These batteries are also much less toxic than older batteries and better battery technology is producing very rapid charge times (90% charged in 5 minutes).
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How EVs Work
Unlike the complex petrol engine which has over 400 moving parts the electric motor in an EV is extremely simple.
In a practical sense the only work required on an EV is maintaining the electrical system, transmission repairs and tyre rotation.
There is no requirement for servicing and replacement of spark plugs, engine oil, oil filters, air filters, and timing belts. There is no need for emissions tests.
Electric motors are probably the most efficient systems for propelling cars. With between 85% and 95% of the energy being used in the motion of the car; this is in contrast to the internal combustion engine which is only 15 - 40% efficient at converting fuel energy to motion.
Modern electric motors utilise efficiency measures such as regenerative braking which allows energy to be recovered during the braking process and returned to the battery pack, and they consume no energy when the car is stationary.
There is also no need for the costly and time-consuming establishment of a complex refuelling infrastructure. Electric cars can plug into any standard power point and charge off the grid.
Electric vehicles can be charged from a variety of sources, including coal and renewable sources however, charging electric vehicles from green power can deliver the greatest carbon reductions.
Overnight charging of electric cars means that they are using power that would not have been used anyway, and thus it is possible to introduce many electric vehicles to the transport mix without building new power stations.
Electric vehicles have many benefits and while they cannot meet the demand of all Australia’s transport needs they are highly viable urban transport option.








