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Design and Development of a Swappable Battery System for Electric Tricycles

Development and Validation of a Cost-Effective Electric Conversion Kit for Conventional Tricycles.

Fastrac Lite

Overview

As part of the Fastrac Lite Electric Tricycle Conversion Project, I led the design, simulation, validation, and fabrication of a modular swappable battery system intended to power converted electric tricycles.

The objective was to develop a safe, reliable, and cost-effective battery solution that supports battery swapping operations while meeting the energy requirements of daily tricycle transportation. The system was designed to simplify charging logistics, minimize vehicle downtime, and provide an affordable pathway for conventional tricycle operators to transition toward electric mobility.

The project involved battery sizing, drive cycle analysis, enclosure design, structural and thermal validation, fabrication, and prototype testing.

Battery System

Problem Statement

Rising fuel costs and vehicle maintenance expenses continue to affect tricycle operators throughout the Philippines. While electric vehicles offer substantial operational and environmental benefits, the high upfront cost remains a major barrier to adoption.

This project addresses this challenge by developing a practical electric conversion kit capable of transforming existing tricycles into reliable electric vehicles while maintaining safety, performance, and affordability.

Design Objectives

Design a reliable battery system
Meet safety and regulatory requirements
Validate structural and thermal performance
Fabricate and test a working prototype

Engineering Design Process

1 Literature Review & Benchmarking
2 Vehicle Assessment & Packaging Study
3 Drive Cycle & Energy Requirement Analysis
4 Standards & Regulatory Review
5 CAD Design & System Integration
6 Structural & Thermal Simulations
7 Fabrication & Assembly
8 Testing & Validation

CAD Development

Structural Simulation

Thermal Analysis

Final Assembly and Integration

Skills Applied

Engineering Data Analysis
Battery System Design
3D CAD Modeling
FEA Simulation
Structural Analysis
Thermal Analysis
Metal Fabrication
Prototype Development
Testing & Validation

Project Outcome

The project successfully demonstrated the feasibility of converting conventional tricycles into electric vehicles using a practical and affordable conversion kit. The developed system achieved the targeted operational requirements while maintaining safety, reliability, and manufacturability.