Integration and Validation of an Embedded Electric Drive System for EV Conversion Kits: A Practical Industrial Case Study

This paper presents the integration and bench validation of a modular electric vehicle (EV) conversion kit, detailing the system architecture, communication interfaces, and real-time performance analysis of its core subsystems. The study systematically examines the key components of the propulsion system—including the electric motor and its associated motor control unit (MCU), the battery pack governed by a battery management system (BMS) with an integrated power distribution unit (PDU), and essential peripherals such as the DC-DC converter, 12 V auxiliary battery, and human–machine interfaces. The central focus is placed on the Controller Area Network (CAN) communication interfaces that enable seamless data exchange and coordinated control among the Vehicle Control Unit (VCU), MCU, and BMS. Through empirical data acquired from the integrated EV kit on a test bench, we conduct a real-time performance analysis to evaluate system responsiveness and drivability under various operating conditions. The findings validate the technical viability of the modular conversion kit and provide a practical reference framework for future EV conversion projects. Furthermore, the paper extends beyond technical integration to assess the economic benefits of EV conversion, comparing operational and maintenance costs against traditional internal combustion engine benchmarks. The study’s scope is limited to system integration and bench validation; vehicle-level integration (chassis mounting, mechanical adaptation, and road testing) is identified as a necessary next step.