PROTON Green Mobility Challenge 2012

PGMC2012 is an initiative of PROTON, together with Agensi Inovasi Malaysia, to promote electric vehicles. Teams compete to build the best performing EV based on a standard 2nd generation Proton Saga.

Day 2: Fastest Time & V-Max

In the afternoon, two challenges were held together: Challenge 2: Fastest Time for 2 Laps and Challenge 3: V-Max

Day 2: Pit Walk

In between Challenge 1 and Challenge 2 & 3, the organisers provided some time for a pit walk session. Spectators are allowed to go into the pits to mix with team members and look closely at the electric cars.

Day 2: Quarter Mile Acceleration

The second day is the day of 'performance' challenges. It started with the scrutinising and safety inspection of the cars. Then, Challenge 1: Quarter Mile Acceleration starts.

Day 1: Pit Display

While most of the team work on the car, some members focused on sprucing up the pit. This is because there are also prizes on team identity and pit display.

Day 1: Registration & Practice

It's October 5th, and finally, we're in SIC. The first day started with the registration and scrutinising of all 10 cars by the PGMC 2012 TC. Only four team members were allowed to be present during the inspection.

Battery Management System

When using batteries as the power source, a battery management system (BMS) is very important. We use the Orion Li-Ion BMS.


As an electric vehicle, the batteries used in the car has to be charged from time to time. The 12 V lead-acid car battery also has to be charged while the car is running.

Thermal Imaging

In order to get an idea of where the hottest and coolest parts of the components might be, we made use of a thermal imager.

Saga Model Incompatibility

When PROTON initially gave us the car, it was a Saga BLM 1.3 model. However for this competition, PROTON then decides to standardise the cars, based on the Saga BLM 1.6 model.

Controller Programming

The motor controller given to us was preprogrammed. To win a race however, one has to evaluate the objective of the race and tune the controller accordingly.

Track Familiarization Day

On 17 September, teams were again invited to the Sepang International Circuit, where the challenge will be held, for driver circuit familiarization.

Thermal Management

Thermal management consists of the management of heat dissipation of the motor, motor controller and lithium-ion batteries with different methods.

Test Drive

The I.C.E. Terminator EV is moving!

Completing The Circuit

With the new electric engine in place, we reconnect all the wires and install the vacuum pump. Put the tyres back on and it's system go.


We have had some problem with adapting the transmission to fit the motor and the car. But finally, we got the parts together and mounted the new electric engine.

Battery Compartment

For the purpose of safety and thermal management, the batteries must be enclosed in some sort of compartment.

Component Assembly

The concept of ICEV to EV conversion is simple enough where the original engine is to be replaced with the electric motor provided by the organizer.

Third Progress Update

Following the previous visit, PROTON and the PGMC2012 Technical Committee visit the teams again for the third progress update. They visited us on 14 August.

In-Car Wiring

Now that the car and its electrical engine system are together in the EV Lab, the wiring of the two can be integrated together.

Monday, 30 July 2012

Testing Motor 2

After confirming that the motor and controller are working properly, we improved the test to more closely resemble the actual situation.
  1. We use an array of 12 V lead-acid batteries to replace the DC power supply.
  2. We use the accelerometer pedal from the car to replace the throttle potentiometer.
Assembling batteries
Pedal wired in
More heavy-duty wiring

Tuesday, 24 July 2012

Second Progress Update

After the first progress update at MITC, PROTON and the PGMC2012 Technical Committee visit each university for the second progress update. This allows them to see for themselves the progress each team is making in carrying out the Proton Saga EV transformation. They visited UKM's I.C.E. Terminator on 18 June.

The visit was started with a presentation a la the previous one in Malacca. Then we dropped in on the Power Machine Lab where the Technical Committee inspects the progress with the motor and battery systems. After that, we went to see the car at the Engine Workshop.

On the whole, the visit went well and we hope to keep up the momentum.
Team leader started the presentation
At Power Machine Lab
At Engine Workshop

Friday, 20 July 2012

Testing Motor

Before using the motor in a car, we first tested the motor (and the controller) in free-running mode, i.e. without load. We also decided to power these two using DC power supply, rather than the battery pack. This allows us to test the batteries separately.
Controller done
Motor hooked up

Monday, 16 July 2012

Electric Vehicle Battery

An electric vehicle battery (EVB) is a rechargeable battery used for the propulsion of battery electric vehicles (BEVs). For this PGMC 2012, PROTON gave each team 13 units of Lithium-ion batteries.



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