Don's Pages and my Music

Friday, October 22, 2010

Advanced electric vehicle conversion project


Here is some good info that I found on selecting the Electric Motor and the Controller, to build or convert a gas automobile to an Electric Vehicle (EV) Car. Check out more info in the Links at the bottom too... 

Don 

The motor
Manufacturer - Siemens AG
Cost - $2,000 in 1998 (non-production prototype)
Production motors available from Metric Mind Engineering

AC motorAs you can imagine, the motor is the heart of the car, often defining (and limiting) its performance. My choice was 3 phase AC induction motor rather than common DC motor used in probably more than 95% of all conversions. We're not going to debate advantages or disadvantages of AC vs. DC motors. It's like debating advantages of the flat TFT screen monitor vs. CRT tube monitor. Both have their uses, but in general if one thing is more expensive and preferred by a pros, then it's not for nothing. Price aside, I have heard a lot about all kind of issues with brushes and brush plate advancing, and didn't want to deal with them. DC motors are (relatively) low voltage high current devices. At high voltages (>200VDC) the brushes will arc especially at high RPM. AC motors are made either way. High voltage units reduce I2R losses and weight of wiring. All you need is to match control electronics to the motor characteristics. I'm only going to say that while my Siemens AC setup (including electronics) is only about 1.5x more expensive than comparable raw power DC setup, it offers much more than 1.5x worth of advantages. To name a few: regenerative braking (actually also available in high end DC systems), electronic reverse, integrated components (main contactors and DC-DC converter), ability to adapt exact characteristics of the motor (and also throttle and brake potentiometers parameters, battery and other hardware parameters) via software, lack of brushes, high top RPM limit (about 10,000 for this motor, more on that - later), water cooling and high reliability.
But the fundamental disadvantage I see in the common DC solutions for EVs is using controllers and motors which are not designed or intended to be used in EV and even in outdoor environment (like common Curtis PMC controllers). At best, controllers for the fork lifts and golf carts are in common use. The same with motors. Most common ones, made by "Advanced DC motors" (can anyone tell me what exactly is advanced in these motors?) can't even normally run in both directions without some modifications! People adapt this hardware for EVs and push its limits because dominating factors are the price, availability and experience of the past, when nothing better was out there. Until recently, I was not  aware of any controllers and motors designed specifically for EV.
Amodern PC or laptop has more than enough computing power to read the sensors, synthesize a 3 phase sine wave and calculate the frequency and amplitude of the voltage applied to the motor. Yet no one would dare to run their EV off of a PC bolted to the fender or laptop in the glove box. It may be acceptable for design experiments stage in the stationary lab environment, but with the temperature, shocks, vibrations and moisture extremes it's totally inadequate hardware. Why not use components intended for the job? The same about the motors and especially controllers, you will put much effort to add some more hardware (also non-automotive grade) like main and reversing contactors, precharge resistors, throttle pots, heat sinks, fans, interlock safety relays to make non-EV controller work in your EV. If integration is done right and generic components are beefed up, this will work for quite a while, I had such setup done. But it's like laptop in the EV, you can't trust it not to fail when you rely on it. Eventually it will fail, just like controller not designed from ground up with EV environment in mind.
I knew about EV AC solutions and all the advantages it provides when I built my first DC CRX. AC Propulsion's CRX was my inspiration making me hunt for this particular donor vehicle. I wanted it so bad that bought perfectly normal functioning used CRX and pulled the engine out. I still have it. I also knew, that one day I will build something much better, comparable to Alan's CRX, with the components intended for the job. Well, this day have come.
The main difference I perceive as a driver is flat torque/RPM characteristic of an AC induction machine. DC motor has giant torque at stall and it quickly diminishes as RPM goes up forcing you to shift gears. So, up to some point I feel constant acceleration on the particular gear, and above that - constant power (torque reduced proportional to RPM). That's what we want. Particular motor I used is made by Siemens, type 1PV4133WS20. Mid power high torque version. The rated continuous mechanical power is 30 kW. The max power is limited to about 80 kW by the inverter, the actual max power for the motor itself is unknown but is way more than inverter limitation. It is water cooled 3 phase 4 pole induction machine weighting about 150 lb. More information on it can be found on my Metric Mind Engineering web site. It is similar to 1PV5133 motors series, just different mounting flange and shaft option. The splined shaft is only about 30 mm long - something I worried about in the beginning, but it turn out to be well thought out and desirable feature. Without it the motor probably wouldn't fit across my engine compartment.
The motor has hall effect shaft speed sensor (two 64 teeth gears with 90° offset) as well as two winding temperature sensors. This info is fed into the power inverter and whole system works in sync adjusting frequency and amplitude of the voltage applied to the motor to control electrical slip for maximum performance and efficiency and reducing drive current in case of overheating. The motor flange is centered to the adapter plate with the round 230 mm diameter ring, recessed 8 mm into the flange. The motor mounted to the plate with four M14 bolts. For supporting  the back side of the motor, special bracket linked to the rubberized engine support was made. (This support was removed in previous conversion because interfered with the back of the small DC motor running air conditioner compressor. Well, this time I needed it back, so I had to visit nearest wrecking yard, cut out this engine support and weld it in place, restoring original look. Turn out looking pretty well.)
Motor The Siemens 3 phase water cooled induction motor, type1PV4133WS20
Motor The motor splined shaft. Outer round centering recess is also visible.


The power inverter.
Manufacturer - Siemens AG
Cost - $3,800 in 1998
Available from Metric Mind Engineering

Long AC             inverterThe power AC inverter is the main part of the electrical system of the car, and its role is simple - to convert the battery energy to the form useable for the AC motor, and to deliver right amount of this energy per driver's demand. While it doesn't sound too complicated, to perform this task flawlessly the electronics gets quite complex, and it is especially true for AC drive systems. In my case inverter has to:
- Convert (invert) the DC battery voltage to the 3 phase AC voltage;
- Adjust AC voltage amplitude and frequency based on the drive current demand and instant conditions like RPM and torque
- Provide regenerative braking turning the traction motor into a generator for recuperating kinetic energy back to the battery pack; so it has to convert generated 3 phase AC voltage back to DC before feeding the batteries,

My inverter is doing all that and much more - it also provides 12V DC voltage to run accessories in the car, hosts main contactors, displays running parameters on the screen of any PC attached to it through RS232C port, protects itself from over voltage, over current, over heating, basically over-anything, protects the motor from overheating and overload, protects the traction battery pack from under voltage during acceleration, from over voltage during regen, signaling faults, storing variable parameters in its non-volatile memory, allows to make timing diagrams of relevant internal signals and bunch of other useful things. Learn more about it here. It is made by Siemens corp. specifically for use in electric vehicles and therefore has all EV stuff implemented and debugged. The maximum battery current is 280A and the battery voltage 380 VDC which makes it about 100 kW inverter. Turns out it's pretty efficienttoo - about 94%. Since it is liquid cooled, I was hoping to run cooling water through the stock heater core and get away without additional heater. Well, because it's wasting very little energy, even when I run the car at 65 mph the water gets barely warm.
inverter Siemens Simovert 6SV 100 kW water-cooled 3 phase AC Inverter with integrated 90A max DC-DC converter and main contactors.
inverter No way I could resist to take the cover off to take a look at this beauty. I've seen a lot of hardware. This one is a piece of art

Read more...
http://www.metricmind.com/ac_honda/main2.htm

Electric Vehicle (EV) History, Ford, Edison and the Cheap EV They Tried to Make
UPDATE 1-Ford invests $135 mln in Michigan plants, add jobs | Reuters
Ford’s Electrifying Plan to Boost Efficiency | Autopia | Wired.com
FRED ALLISON - Google Patent Search
OF DETROIT - Google Patent Search
STARTING DEVICE - Google Patent Search
Brougham (car body) - Wikipedia, the free encyclopedia
Car body style - Wikipedia, the free encyclopedia
1914 ford cabriolet body - Google Search
1914 Ford Touring Car Picture, Classic Car Pictures
1915 Brougham - Search results - Wikipedia, the free encyclopedia
1915 Ford Brougham - Search results - Wikipedia, the free encyclopedia
Brewster & Co. - Wikipedia, the free encyclopedia
Brewster & Co. - Wikipedia, the free encyclopedia
Howell's Sheetmetal Co. - Model A Ford & Model T Ford Parts
1915 Ford cabriolet - Search results - Wikipedia, the free encyclopedia
Volvo Cars - Wikipedia, the free encyclopedia
Ford Edison Electric Car - Google Search
Ford, Edison and the Cheap EV - Search results - Wikipedia, the free encyclopedia
Electric car - Wikipedia, the free encyclopedia
History of the electric vehicle - Wikipedia, the free encyclopedia
Timeline: History of the Electric Car . NOW on PBS
Ford Edison Electric Car - Search results - Wikipedia, the free encyclopedia
Ford Motor Company - Wikipedia, the free encyclopedia
Detroit Electric - Wikipedia, the free encyclopedia
File:1915 Detroit Electric.jpg - Wikipedia, the free encyclopedia
File:Detroit Electric 1916.jpg - Wikipedia, the free encyclopedia
File:1920DetroitElectricAd.jpg - Wikipedia, the free encyclopedia
Electric vehicle - Wikipedia, the free encyclopedia
File:Jedlik's electric-car.PNG - Wikipedia, the free encyclopedia
File:Electric car and antique car on display at 1912 auto show.jpg - Wikipedia, the free encyclopedia
File:GM EV.jpg - Wikipedia, the free encyclopedia
Smith Electric Vehicles - Wikipedia, the free encyclopedia
Thomas Edison - Wikipedia, the free encyclopedia
File:Edison bulb.jpg - Wikipedia, the free encyclopedia
File:Menlo Park Laboratory.JPG - Wikipedia, the free encyclopedia
File:Edison and phonograph edit1.jpg - Wikipedia, the free encyclopedia
File:Thomas Edison, 1878.jpg - Wikipedia, the free encyclopedia
File:Light bulb Edison 2.jpg - Wikipedia, the free encyclopedia
File:PyramidParthenon.jpg - Wikipedia, the free encyclopedia
Henry Ford and the electric car at Hemmings Blog: Classic and collectible cars and parts
File:Detroit-electric 1912 logo.jpg - Wikipedia, the free encyclopedia
File:Kilowatt.jpg - Wikipedia, the free encyclopedia
File:Front shot - Detroit Electric 1917 taken in Maffra, Vic, 2007.jpg - Wikipedia, the free encyclopedia
File:Bundesarchiv Bild 183-1990-1126-500, Kraftdroschke.jpg - Wikipedia, the free encyclopedia
File:Detroit Electric car charging.png - Wikipedia, the free encyclopedia

Electric Powered Vehicles & Parts
Electric Vehicles USA, Inc
Our Solution - Flexible Components
Our Solution - Products
Fasco Electric Motors - 5.6 Diameter
Advanced electric vehicle conversion project
High End AC Drive Systems and Power Electronics for Electric Vehicles
DonsDeals: Advanced electric vehicle conversion project

Electric Powered Vehicles
electric powered vehicle - Google Search
A Student's Guide to Alternative Fuel Vehicles - Electric Vehicles
EV WORLD: The Eco-Friendly World of Electric Cars, Hybrids, Plug-In Hybrids, Hydrogen Fuel-Cell Vehicles from Bicycles to Buses, Trucks to Trolleys.
Electric Vehicles USA, Inc
EVT News || Electric Vehicle Technologies
ZAP Smart Car, 100% Electric EV, Hybrid, Fuel Cell, Alternative Vehicle, Portable Energy
Electric Vehicles USA, Inc
Howstuffworks "Electric Car Conversion"
Howstuffworks "How Electric Cars Work"
Howstuffworks "An Electric Car Example"
Howstuffworks "Inside an Electric Car"
Howstuffworks "Inside an Electric Car"
Howstuffworks "Electric-car Motors and Batteries"
Howstuffworks "Charging an Electric Car"
Howstuffworks "How the Tesla Roadster Works"
Howstuffworks "Tesla Motors and the Future of Electric Cars"
Howstuffworks
Howstuffworks "Lots More Information"
ZAP | Ride The Future
ZAP-X | ZAP
Offroad EV | ZAP
pbs electric auto - Google Search
Electric Auto Association - Electric Vehicles and Cars
Electric Automobile Association Google Search
Electric Automobile Association Google Search
2008 Honda FCX - AutoWeek Magazine
Solar - House and Cars
Electric Automobile Association Google Search
Zebra sodium/nickel battery - Google Search
Green Car Congress: The ABSOLUTE Hybrid: Combining a Solid Oxide Fuel Cell with a ZEBRA Battery
Driving on Sunshine
Molten salt battery - Wikipedia, the free encyclopedia
convert battery to sodium nickel battery - Google Search
Cobalt oxide passivation of nickel battery electrode substrates - Patent 5248510
Who Killed the Electric Car? NOW | PBS
Sony Pictures Classics Presents : Who Killed the Electric Car?
Sony Pictures Classics Presents : Who Killed the Electric Car?
who killed the electric car watch free - Google Search
Watch "Who Killed The Electric Car?" online - for now - AutoblogGreen
AutoblogGreen
AutoblogGreen - Pics
AC Electric Motor - Google Image Search
Electric Motor
Hybrid Attack - Autoblog
Hot Rod Carts
Google Image Result for http://www.cprmotor.com/products_img/Single_three_phase_ac_asynchronous_electric_motors_IMB34.jpg
Ac electric motor, High Speed Industrial Electric Motors Manufacturer India
Grantham Electrical
AC Electric Motor car - Google Image Search
Toyota Prius Hybrid Car Technical Information
X1 ELECTRIC CAR IAN WRIGHT
General Motors EV1 - Wikipedia, the free encyclopedia
electric motor car - Google Search
China Electric Motor Car Manufacturers & Suppliers
Electric Car Hub Motor
ELECTRICAL CAR MOTOR
AC Motor for electric car
electric motor car - Google Search
EVAlbum: Build Questions
High End AC Drive Systems and Power Electronics for Electric Vehicles
High End AC Drive Systems and Power Electronics for Electric Vehicles
Steve Hawkins' 1998 Chevrolet S-10E
EV Photo Album: Our Electric Cars on the Web
John's 1986 Nissan King Cab
Roger Layola's 1988 Puch Condor III
EV Tradin Post: Electric Vehicle Classifieds
electric motor car - Google Search
ZENN Motor Company
AC Electric Motor car - Google Image Search
e-Traction® Direct Drive Technology (TheWheel™)
Traction Wheel - The Wheel - Types & Models
e-Traction - a revolution in motion™ - & - moving the future™
Production Volt could be the guest of honor at GM Centennial party! - AutoblogGreen
AutoblogGreen
ZENN Motor Co - Google Search
ZENN Motor Company
Baker Rauch & Lang, Baker-Raulang, Jacob Rauch & Son, Raulang Body, Rauch & Lang Carriage Co., - Coachbuilt.com
Electric Powered Vehicles
Grantham Electrical
ELECTRICAL CAR MOTOR
Toyota Prius Hybrid Car Technical Information
Electric Motor
Howstuffworks "Tesla Motors and the Future of Electric Cars"
X1 ELECTRIC CAR IAN WRIGHT
EVT News || Electric Vehicle Technologies
Molten salt battery - Wikipedia, the free encyclopedia
Watch "Who Killed The Electric Car?" online - for now - AutoblogGreen
Electric Automobile Association Google Search
AutoblogGreen
EV WORLD: The Eco-Friendly World of Electric Cars, Hybrids, Plug-In Hybrids, Hydrogen Fuel-Cell Vehicles from Bicycles to Buses, Trucks to Trolleys.
Sony Pictures Classics Presents : Who Killed the Electric Car?
General Motors EV1 - Wikipedia, the free encyclopedia
ZAP | Ride The Future
ZENN Motor Company
Steve Hawkins' 1998 Chevrolet S-10E
EVAlbum: Build Questions
EV Tradin Post: Electric Vehicle Classifieds
Traction Wheel - The Wheel - Types & Models
Hot Rod Carts
e-Traction - a revolution in motion%u2122 - & - moving the future%u2122
Howstuffworks "How Electric Cars Work"
Howstuffworks "Electric Car Conversion"
Production Volt could be the guest of honor at GM Centennial party! - AutoblogGreen
Roger Layola's 1988 Puch Condor III
AC Motor for electric car
e-Traction? Direct Drive Technology (TheWheel%u2122)
Howstuffworks "Inside an Electric Car"
Sony Pictures Classics Presents : Who Killed the Electric Car?
Google Image Result for http://www.cprmotor.com/products_img/Single_three_phase_ac_asynchronous_electric_motors_IMB34.jpg
EV Photo Album: Our Electric Cars on the Web
Tortuga electric car - YouTube
Electric car without Battery invented - Government killed inventor! - YouTube
Motorshow - Paris 2012 | Mia Electric
Mia-U-Electric-Car-Back-View
Flight Bikes Launches Pair of 250W Electric-Assist Bicycles - EVWORLD.COM

Electric Tricycle - All-Terrain Electric Scooter and more Cool Projects by Ben Katz
Electric tricycle build log is like hacker crack
BuildIts: Electric Tricycle
Electric Tricycle: Early Morning Shenanigans - YouTube
All-terrain electric scooter build
BuildIts: All-Terrain Electric Scooter
BuildIts
BuildIts in Progress
BuildIts: Project List
BuildIts: Programming
BuildIts: Art
Electric Scooter Helmet Cam - YouTube
Electric Scooter 2nd Test - YouTube

Electric Dirt Bike
YouTube - The BLADE 04
YouTube - 2010 Zero X Electric Motorcycle - Natural Sound
YouTube - KTM Freeride Electric
YouTube - KTMs new electric model
ZERO X Electric Motorcycle - Specs || ZERO MOTORCYCLES
PCH Search & Win: electric dirt bike
YouTube - 2011 KTM Freeride Electric Bike
ZERO X Electric Motorcycle || ZERO MOTORCYCLES
www.electricmoto.com
Electric Motorcycles
Electric motorcycle hits the racing circuit
PARC - YouTube
Farfle's electrics
Electric motorcycle is awesome, goes 54 mph
Honda VTR 250 tear down for electric motorcycle - YouTube
Hive13 » Project Spotlight: Electric Motorcycle
Build an electric motorcycle
Hive13: Electric Motorcycle - a set on Flickr
Electric Motorcycle first ride - YouTube
Homemade Electric Motorcycle first road ride - YouTube
Build Your Own ELECTRIC MOTORCYCLE
Build Your Own ELECTRIC MOTORCYCLE

Electric Bike Search on Google and PCH
Eco Motorcycles: Motobecane Motivo – An Electric Bike With Removable Batteries - Ecofriend
Electric bike motor, Electric Bicycle motor,Shanghai Maxbright Industry Co.,Ltd.
electric bike conversion kit - CK-01 - YongJiang (China Manufacturer) - Motorcycle Parts & Components - Transportation Products - DIYTrade
2009 Optibike OB1 electric bike | iTech News Net - Gadget News and Reviews
electric Bike kit | electric Bike conversion | electric Bicycle kit | Canada | Alberta | Calgary | e-bike | ebike | electric Bicycle conversion kit | folding bike | electric recumbent | electric trike | electric folding bike | electric conversion kit | electric recumbent bike | recumbent bike | electric scooter Canada | etrike | e-bike | bike conversion kit | CrystaLYTE Journey Kit | BMC Trek | Worksman | Norco | Giatex | Dahon | kuwahara | sun bicycles | EZ tandem | ez3 trike | hybrid | Wilderness Energy | crystalyte | Phoenix, RoadRunner, Sparrow, bionx | BL36 | BD36 | BL-36 | BD-36 | Bion X |electric bike Calgary | electric bike Canada | electric bike Ontario | Electric Bike Vancouver | Crystalyte | electric moped Calgary | alternative transportation | Giatex | Dahon | electric skateboard | e-ride | TidaForce | Power In Motion | itelectric | Electric Bicycle | nicad battery | NiMH battery | fuel cell | Lithium battery | li-ion | power bike | power bicycle | Power In Motion | hybrid | alternative transportation
Cycling and Wheel Sports: Schwinn 20" Stingray 250-watt Electric Bike S2938
Electric bike motor, Electric Bicycle motor,Shanghai Maxbright Industry Co.,Ltd.
British Electric Bike to Race in Zero Emissions Grand Prix - Gearlog
26″ Wheeled eZip Trailz Electric Bike!
TreeHugger Forums • View topic - Europe's latest craze: Electric bikes
Eco Motorcycles: ZEVS All-electric Motorcycle Is Packed With Aggression And Speed - Ecofriend
ELECTRIC CYCLES AND CHINA CRACK DOWN ON UNTRAINED RIDERS NELSON KRUSCHANDL
electric bike : Bicycles
Ultra Motor A2B Electric Bike - Minus Celsius - First Aid to Boredom
Honda Oree Concept Electric bike | Future Motorcycles
electric bike - Google Search
PCH Search & Win: electric bike
Electric bicycle, electricbike
Electric Bikes, Scooters and other Light Electric Vehicles (LEV)
The-Bikes | optishop
Save Up To 60% Off Road Bikes, Bicycles, Mountain Bikes and Bicycles with Bikesdirect.com, New with full warranties
Electric Bikes Northwest
http://www.electricmoto.com/
ZERO X Electric Motorcycle || ZERO MOTORCYCLES
Electric Bike Hire - Saxmundham
electric bike - Google Search
electric bike - Google Search
Regional government wants companies to switch to electric bikes — Autoblog Green
PICAXE-08M Electric Bike
Future Transportation -
Inventor's dream of electric bike brought to life
Picture: Other - Zero X Electric Bike DSC 0130
The LongRanger electric bike - SlipperyBrick.com
electric atv - Dirt Bikes
Eco Bikes: Pannon Rider – Solar-powered Bike Saves You From Harsh Weather - Ecofriend
Betterbikes - Electric-Bikes.com
The Legend of the Motorcycle - 2007 - Featured News


No comments:

Post a Comment