Optimizing Efficiency and Extending Battery Life in Electric Vehicles: A Comprehensive Analysis of System Components and Design Strategies

The urgency for environmentally friendly transportation solutions has driven the rapid expansion of the electric vehicle (EV) market, revolutionizing the automotive industry. This paper provides an in-depth analysis of EV system topology, highlighting essential components, structures, and interactions that ensure efficient and reliable operation. Key aspects of an electric powertrain-based vehicle are explored, including the battery pack and motor. The study details the main components of an EV system-control unit, power electronics, energy storage (battery), and electric motor-which collectively support propulsion, energy storage, and overall functionality. A practical component of this research involved converting an old petrol vehicle into an electric vehicle to validate theoretical calculations and predict battery life and efficiency. Emphasis is placed on the control unit and power electronics for managing power flow, and the battery system for its capacity and lifecycle efficiency. The electric motor’s performance is assessed based on torque and power output. Efficiency improvements through modifications in aerodynamic drag coefficient (CA), mass (M), and rolling resistance coefficient (Crr) are analyzed, showing significant gains. Reducing CA from 0.7 to 0.6 improved efficiency by 4-13%, lowering mass from 180 kg to 160 kg increased efficiency by $0.9-8 \%$, and decreasing Crr from 0.004 to 0.003 led to $2-18 \%$ efficiency gains. Battery life predictions indicate that lower speeds considerably extend battery life, with approximately 51.27 hours at $10 \mathrm{~km} / \mathrm{h}$ and 1.02 hours at $55 \mathrm{~km} / \mathrm{h}$.