by RMIT University design student Alexander Burton, the winner of this year’s Australian national Dyson Award, has unveiled plans to develop a bolt-on retrofit kit that can convert internal combustion engine (ICE) cars into practical and efficient hybrids for less than US$3,200. The REVR (Rapid Electric Vehicle Retrofits) kit aims to provide a cost-effective solution to decarbonize driving without the need for purchasing a new electric vehicle or hybrid.
The centerpiece of the REVR system is a flat, power-dense, liquid-cooled 50-kW motor that can be installed between the wheel and brake disc. The pancake-style axial flux motor features a flat stator plate that bolts to the back of the wheel hub and a rotor plate that delivers torque through the wheel bolts. Each car model requires an adapter plate, but installation is expected to be a quick and simple task, taking around 10 minutes without requiring specialized knowledge.
The battery pack and motor controllers will be located in the trunk, where the spare tire would typically be stored. By utilizing the spare tire space, the kit has room for approximately a 15-kWh battery pack, providing over 100 km (62 miles) of all-electric range at stop-start city driving speeds with regenerative braking. This range is sufficient for the majority of daily driving needs for most individuals.
The REVR kit is designed to work in parallel with the combustion engine or operate independently. Users can turn the ignition key to the “on” position and activate the electric drive by flipping a separate switch. If the ICE engine is not running, the battery pack will keep the regular 12-V battery charged to power headlights and other electrical components. The kit also includes electric replacements or augmentations for components such as air conditioning, heating, power steering, and brake boosters that typically rely on belts from the engine.
To read the accelerator pedal, Burton is considering using a potentiometer or similar device to determine acceleration and regenerative braking, similar to existing hybrid vehicles. The system may require a way to shut off the electric motor or enable reverse operation when the car is in reverse gear. While a dash display for battery level is not planned for basic conversions, diagnostics may be accessible through a mobile phone app to ensure simplicity in operation.
The REVR kit aims to be a zero-footprint retrofit, with plans to target approximately 20% of mainstream car models, starting with popular models like the Corolla, Accord, and Civic groups. The installation is expected to be carried out by local mechanic workshops that undergo training from REVR. The target pricing for a fully installed dual-motor, 15-kWh kit is less than AU$5,000 (US$3,200), making it an attractive option for car owners.
However, the legality of the modification needs to be navigated, with updated legislation and engineering certification required. Burton believes that updated legislation will eventually allow the modification, and his team may provide the necessary certification in-house. The first car to undergo conversion will be Burton’s 2001 Corolla, with a target availability of the kit in Q3 of next year.
Burton envisions the REVR kit as a means to decarbonize driving and make it accessible to a wider audience, without compromising safety or functionality. While the initial focus is on offering a minimally-invasive 15-kWh kit, Burton hopes to expand the offering in the future to enable complete removal of the combustion engine and a shift to fully electric powertrains. The modular and minimalist structure of the REVR kit is expected to reduce the cost of such conversions significantly compared to traditional electric vehicle conversions.
The REVR project has attracted significant interest, with potential investors and crowdfunding opportunities being explored. The ultimate goal is to convert one million cars, providing an affordable and sustainable solution for car owners seeking to reduce their carbon footprint. Although there are challenges ahead, including ensuring reliability, safety, functionality, and legal compliance across various car models, the progress of the REVR project will be closely followed.
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- Source: Coherent Market Insights, Public sources, Desk research
- We have leveraged AI tools to mine information and compile it
