Solar Powered Car Generation for DIY EV Conversion



Can I use solar panels on my electric vehicle to generate power when I drive or park?  This is a question that I asked myself years ago and I was asked about this again recently.  The short answer is, yes.  The real underlying question is how much power can be generated using solar panels on a vehicle while it is sitting idle parked all day in the sun.


To be the most accurate of the different types of solar panels need to be identified.  In particular, the solar panels for this use would use the solar photovoltaic effect to use photons which stimulate the electrons in the panel, in the end generating electricity.  If you are looking for more information on how this works you can check out for further reading.


Types of Solar Panels

There are three solar cells monocrystalline, polycrystalline, and amorphous.  If you do not understand what this means, that is okay.  The important part to take away from these types is that the solar cells are available in different cell structures.  Monocrystalline and polycrystalline are similar as they are made from crystals and are either left separate or strung together in the case of polycrystalline.  Amorphous cells use a thin layer of silicon.  With each type of solar cell, there are advantages and disadvantages which include rigidity, low light ability, cost, and efficiency to generate power.


Monocrystalline Polycrystalline Amorphous
Semi-flexible / Rigid Semi-flexible / Rigid Bendable
15-24% 13-18% 20-25%



To provide the best chance to charge deep cycle batteries, the most available area will be assumed for this case study.  I will use a 2002 Ford Ranger regular cab 4×2 with a hard cover over the bed.  In this case, the solar panels would be mounted on the cab roof and over the bed.  It is worth mentioning that a custom framework would have to be fabricated to mount all the solar panels as well as to route all wires to a battery charging device.  The battery charger would have to protect the batteries from overcharging.


The area available for solar panels on the bed of a short wheelbase, 6-foot bed, would be 77 inches by 52 inches.  On the cab roof, there would be 52 inches by approximately 35 inches for solar panels.  These sizes are based on the truck dimensions found here.


To give the best result for the solar charging I have selected a flexible amorphous solar panel from Amazon.  This will keep the thickness of the panel low, which would, in turn, keep the change in air drag at a minimum.  The solar panel is listed as 41.3” x 21.25” x 0.12” thick.  With this particular solar panel, it would mean that one panel can be mounted on the cab roof and three can be mounted on the bed hardcover.  As for the solar panel coverage, area, this works out to be 3,553 square inches or 2.29 square meters.


Solar Panel Charging Equation

The equation (found at to find the energy generated from solar panel system is the following, E = A * r * H * PR and can be in this equation E is the total energy generated in kWh units.  A is the total solar panel area in meters squared, m².  The solar cell efficiency that is listed above is the r unit as a percentage.  The H unit is the annual average solar radiation on tilted panels, which is dependant on your geographic location.  The solar radiation data for your region has already been collected and is available in a database from photovoltaic-software.  The last variable is performance ratio (PR) for all the variables that affect the losses of the system which include losses due to the cables, converter, dust, and temperature losses, to mention a few.


E = A * r * H * PR


To plug in some of the holes of this equation I’m going to make some assumptions for H and PR.  The solar radiation for each area will be different and will affect the energy generated.  With that being stated again, I have selected Atlanta, Georgia for the H value, which has an annual average of 5,080 Wh/m²/day or 5.08 kWh/m²/day.  For the performance ratio (PR) the percent of losses from all the equipment outside of the panels itself to be 75%, as the default value.


Using the equation now with the following variables:


A= 2.92 meters squared

r= 0.20 or (20% which is the lowest of the efficiency range between 20% and 25%)

H= 5.08 kWh/m²/day for Atlanta, Georgia

PR = 0.75 or (75% performance efficiency)

E= 2.225 kWh


P= E / t

t= 12 hours of average sunlight per day for Atlanta, Georgia

P= 0.185 kW


This is assuming the vehicle is left outside during the whole day, either at home or work.  There is an average of 12 hours of daylight in Atlanta.  The power generated is 0.185 kW which is calculated by dividing the energy generated over the course of the day over the amount of average daylight.  Also worth noting, the energy generated is an average, so the energy produced will be higher and lower depending on the time of year and amount of clouds.


With the solar charge from a full day of being in the sun has been determined, the amount of power used to operate the vehicle needs to be determined.  For this case, I am first going to assume that this vehicle is used for a daily commuter.  The length of driving from home to work and back can vary for everyone.  I am going to assume that a half an hour one-way trip to work for this case.  So in total an hour a day for each workday.


Vehicle Power Usage Estimate

There are many factors that will determine the power required to operate the electric vehicle conversion.  Some of these factors include transmission, average vehicle speed, acceleration (which depends on driving style), the difference of overall weight from the original pre-conversion weight, and size of the motor, or if there are two motors.  There are more factors that affect the power required to operate the vehicle, these are the largest factors.


Assume the use of one AC-50 electric motor running with a 72 volts system.  The vehicle speed is assumed to be at highway speed of 65 mph or 105 kph and an automatic transmission.  The motor speed is estimated to be at 2,550 revolutions per minute which would be required to be at highway speeds, as shown on another post for EV conversion transmission analysis and selection.  The current is estimated to be 620 amps and voltage is 75 volts, as per the AC-50 motor performance chart.  As a result, the required power to operate the vehicle at highway speeds is 46.50 kW.


Phwy= 46.50 kW



So the energy required for a commute in one direction will be 23.25 kWh since it is half an hour or 0.5 hours.  A total round trip would end up being 46.50 kWh.  This would be the worst case scenario for a half hour commute.


The best scenario would be a city commute traveling at 30 mph or 50 kph.  With everything else the same, the motor would only need to run at approximately 1180 revolutions per minute to get to city speeds.  Assuming constant speed for the duration of the commute, the current is estimated to be 450 amps and voltage at 75 volts.  The power required to operate the vehicle at city speeds is 33.75kW.


Pcity= 33.75 kW


The energy consumed for both highway and city scenarios are the same values as power due to totaling one hour of power usage, 46.50 kWh and 33.75 kWh respectively.


If you are looking for a refresher on power (kW) and energy (kWh) you can check out for more information.  A quick glance is that power, is work whether consumed or generated, and energy is power with a unit of time.




Results for EV with Solar Panels

Looking at the energy used and generated on an ideal day we can determine the efficiency of the solar panel charging system with regards to the electric vehicle demands.  For the highway commute, the solar panels will generate 2.225 kWh or 4.8 percent of the energy used in the day.  Another way to state this is that if you are planning to charge solely with onboard solar this will take 21 days between drives.


For the city commute, the solar panels will generate 2.225 kWh or 6.6 percent of the energy used in a day.  Again, if you are planning to charge solely with an onboard solar system this will take 15 days between drives.


Another aspect to consider is the amount of energy generated after sitting in the sun while at work compared to the energy used to commute to work.  For a one-way highway commute, the energy consumed would be 23.25 kWh.  As for the city commute, one-way the energy consumed would be 16.88 kWh.  The power generated by the solar panels during a 9-hour workday, assuming an 8-hour work day and an hour lunch, would be 1.67 kW.  For the highway work commute the solar panels will recover 7.2 percent of the power consumed, and 9.9 percent for the city work commute.


To fully recharge the batteries with only an onboard solar panel system will not be enough for a daily commuter.  As a free extra energy boost during the day, solar panel charging does have its merit.  The solar panels will always generate energy while parked outside.   The investment for installing the solar panel system would be around $1000 USD.  Over the course of a month, the solar panels would generate 67.67 kWh.  Based on the rate shown on electricitylocal the average Georgia electricity cost is 11.17 cents / kWh.  In the course of a month, the solar panels would save $7.56, and it would take 132 months or 11 years to cover the cost of the solar panels.


This could be a good option for those who are concerned more about how the electricity is produced over the cost of the panels.  A small investment in the panels may take a while to return the initial investment.  This can provide a little more peace of mind knowing that the electricity is renewable.  Check out the price of the amorphous solar panels on Amazon, or the polycrystalline solar panels.




Here are some other articles if you are looking for more information:


  • Streamlight Launches Vehicle Solar Charging Panel … – , a leading provider of high-performance flashlights, today introduced the Streamlight SolarStream™, a supplemental solar charging panel for emergency responder and fleet vehicles. The Streamlight SolarStream helps to offset battery drain from computer systems and other rechargeable electronics when a vehicle is off, extending battery life and limiting battery-related vehicle maintenance. A thin-film amorphous silicon charging panel, the Streamlight SolarStream adheres to a variety of contoured surfaces.
  • Solar Powered Cars vs. Hybrid Cars – Ways2GoGreen Blog – The more we know and do, the better we all will be. This is a vehicle that utilizes solar panels, usually fitted on the roof of solar sedans (the very few that exist anyway), to convert energy from the sunlight to power its motor. Many (probably most) solar powered cars are built for the racing tournament called “World Solar Challenge” that happens a lot in Australia.
  • How can solar panels power a car ? | HowStuffWorks – Video embedded ᅠ· Solar panels power a car ? Sounds like an excellent idea, especially considering the current gas prices. Learn how solar panels power a car .


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