Integration of solar panel systems to improve the range of electric vehicles

A PROJECT BY

With a fleet of seventy vehicles, fifty-seven of which are electric, the Société du parc Jean-Drapeau (SPJD) needs to improve the range of its electric vehicles specifically used by employees for maintenance activities, which require a high number of round trips and therefore high mileage. To do this, it called on its partner, the Campus de la transition écologique, an organization located on the islands of Parc Jean-Drapeau where experimental projects are tested. The latter put it in touch with CAPSolar, a start-up developing solar energy modules optimized for electric vehicles.

This partnership gave rise to a pilot project. This project to integrate a complementary solar module on three low-speed electric vehicles aims to increase the fleet’s range by improving battery efficiency, with the goal of achieving significant productivity gains as well as a reduction in carbon footprint. Since the Parc Jean-Drapeau’s electric vehicles do not have the range for a full day’s use, CAPSolar’s solution aims to make up the charging deficit and prevent the vehicles from being out of service at a charging station when they are needed.

Project objectives

• Increase the range of the electric vehicles used primarily by employees for maintenance activities by 15 to 20% (equivalent to two shifts, or about 17 hours);
• Reduce stress on battery lifespan by providing an alternative power source;
• Establish a collaboration model between start-ups and established companies to develop sustainable solutions.

1. Project methodology

• Identification of the needs of Parc Jean-Drapeau: vehicle range and charging infrastructure insufficient for effective fleet management;
• Development of three solutions proposed to Parc Jean-Drapeau, one of which was selected;
• Design and development of the prototype: a custom-designed solar panel system;
• Collaboration with European subcontractors for component manufacturing
• Testing period (durability, vibration) and data collection and adjustments;
• Installation and integration of the system on Parc Jean-Drapeau's vehicles;
• Monitoring of system performance via an online platform.

2. Financing

Total budget of $60,000, financed by Parc Jean-Drapeau for $10,000 and $50,000 from the City of Montreal’s Green Innovation Program fund.

3. Results achieved

The project demonstrates that the CAPSolar system helps increase vehicle range by 12 to 17%. The gain is present, but the target was not fully reached. It is interesting to note that when the project began, the SPJD team realized during discussions in the design phase with the CAPSolar team that their technology would probably not achieve the 17-hour target. Despite this, the SPJD decided to go ahead to test the technical performance and the potential of the system, and possibly integrate it differently into its operations. These assumptions proved correct as it was demonstrated at the end of the project that the range gain amounted to about 2 hours. Thus, the SPJD opted to purchase new vehicles with increased range rather than continue investing in solar panel solutions to increase the battery range of its current fleet vehicles. A pioneer in the use of electric vehicles, the SPJD is proud to have tried CAPSolar’s technology and continues the collaboration to improve the system’s performance on the three vehicles concerned.

4. Lessons learned

Success factors

Among the success factors are:

• Importance of understanding the client's specific needs and adapting the solution accordingly;
• Before launching a similar project, the fleet manager must first assess their needs and establish the right parameters in order to compare estimated gains;
• Involve multiple employees within other departments as well to ensure continuity in case a resource leaves;
• Effective collaboration between start-ups and established companies to combine innovation and experience;
• Possibility to evolve and improve the solution based on feedback and changing market needs;
• First commercial project for a young start-up, serving as a technological showcase that enabled the commercialization of similar and larger-scale projects, including internationally;
• Collection and analysis of real-time data via software that captures performance-related information, allowing verification of whether a change in user behavior can impact system performance and thus enabling recommendations.

5. Challenges and practical advice

• Rigorous selection of suppliers to ensure the quality and compatibility of components;
• Ensure compliance of added elements to vehicles to guarantee user safety and comfort;
• Provide for thorough testing periods to validate the performance and durability of the solution.
• The technology offered by CAPSolar is relevant to implement on low-speed electric vehicles that have an almost sufficient range to complete a workday and that experience seasonal losses. However, it is less suited for vehicles whose charging performance must be increased significantly (almost doubled in the case of the SPJD).

6. Things to keep in mind when conducting a similar project

As this is a relatively new market, competitors are scarce and instead become allies to develop solutions together in order to grow larger markets. This first commercial project becomes for CAPSolar a tangible solution to share with potential clients.

7. Next steps for stakeholders

CAPSolar aims to develop solutions for the maritime industry as well as for transportation.

The SPJD is trying other technologies, notably the maxx-ev (small electric van with a cabin usable year-round). It must overcome other challenges, because the use of this type of vehicle is more limited. Indeed, a class 5 license is required and not all their employees are able to comply with this requirement.

Efforts are also underway to assess how to reconfigure part of SPJD’s operations in order to maximize the solar panel technology installed on these three electric vehicles.

Project contact person

• CAPSolar
• Société du Parc Jean-Drapeau : vehicle operator