The need for a technical standard for the conversion of Internal Combustion Engine (ICE) vehicles to electric drive has been identified by government regulators in New Zealand (NZ). The aim of this project was to review the technical and inspection requirements that would allow Electric Vehicle (EV) conversions of passenger vehicles of gross weight < 3500 kg (Class MA), to be safely designed, built, sold, and operated in NZ. A detailed description of the spectrum of EV technology is given. A literature review of NZ and international transport regulations and technical standards has shown many requirements affecting EVs. A risk analysis showed that most EV technological risks related to electrical, battery and braking safety are controlled by implementing a reduction in risk event likelihood, rather than a reduction in risk event severity. This indicates that risk controls need to be reliable in order to be effective. A detailed review of EV electrical systems, Lithium Ion (Li-ion) battery systems and regenerative braking technology is also carried out. With the use of battery chemistries and designs which minimise the risk of failures, coupled with adequate safeguards in the form of redundant protection and well designed component management systems, EV converters can achieve safe and high performance conversions.
