Electric Vehicle Conversion

Electric Vehicle Conversion
Electric Vehicle Conversion
September 25, 2014
Matt Graham
Joule Injected Technologies
Hack and Tell Goals
• Share technical and practical information related to EV components and the conversion
related to EV components and the conversion process
• Provide two detailed examples of cars I
Provide two detailed examples of cars I’ve
ve converted to electric
• Answer any questions at the end of the Answer any questions at the end of the
presentation
• Address specific topics of interest anyone Address specific topics of interest anyone
brings up now, or during the presentation
Who is this guy?
g y
• Mechanical Engineer
– Formerly of EnerFuel, parent company EnerDel
Formerly of EnerFuel parent company EnerDel
• Engineering consultant
– SolidWorks mechanical design & fluid analysis
mechanical design & fluid analysis
– LabVIEW data acquisition and control programming
• Founder of Florida Electric Auto Association
• Board member of National Electric Drag Board member of National Electric Drag
Racing Association
1990 Nissan 240SX EV
•
•
•
•
•
•
•
Converted in 2006
National Electric Drag Racing Association world record h ld f
holder for quickest Street Conversion EV (SC/A class)
k
( / l )
The only Street Conversion EV in the world to break 100 mph in the quarter mile
13.3 second quarter mile, 0‐60 mph in 4.5 seconds
300V, Twin DC Motors, 2000A Controller
25 lead‐acid Exide Orbital batteries
Direct drive with series/parallel motor switching of motor configuration
1978 Porsche 911 SC EV
•
•
•
•
•
•
•
Conversion begun in 2007
150kW AC P
150kW AC Propulsion motor/controller
li
t / t ll
26.5 kWH of Kokam high‐power Lithium Polymer batteries for 120 mile range
370V nominal, 580A maximum output, 200A maximum regen
Custom fabrication of all battery boxes, motor mounts, instrument cluster and enclosures
Custom, professional interior installation
Complete restoration completed prior to conversion to EV
Ground‐up and Motorcycle EVs
1995 Tropica
•Purchased and rebuilt by Matt Graham in 1996
•72V, twin DC Motors, twin Curtis controllers
•12 flooded lead‐acid batteries
Cyclone
•Custom built with business partner in 2005
•800 A controller
•800 A controller
•72V, Permanent magnet ETEK motor
•6 Sealed lead‐acid SVR batteries
Fuel Cell EV
EnerFuel HT‐PEM Fuel Cell Extended Range Electric Vehicle
(fancy name for PHEV)
(fancy name for PHEV)
•3kW HT‐PEM Fuel Cell
•Recharges battery pack while parked or while driving (reduces discharge)
•5000 psi hydrogen tank
•Converted ACP eBox in 6 months (FC system, control & power electronics)
Planning the Conversion
g
• Purpose
– Commuter, autocross, drag racing, cart, motorcycle
,
,
g
g,
,
y
• Performance objectives
– Range, acceleration, top speed, handling
• Finances
– Total budget, operating and maintenance costs
• Vehicle platform
V hi l l tf
– Production glider, kit car
• Skills
– Welding, sheet metal fabrication, wiring
EV Range
• Rules of thumb
– Light, aerodynamic car ~ 150‐250 Wh/mile (4‐6 Li h
d
i
150 250 Wh/ il (4 6
miles/kWh)
– Heavy, boxy car or truck ~ 250‐400 Wh/mile (2.5‐4 H
b
t k ~ 250 400 Wh/ il (2 5 4
miles/kWh)
– Sedate driving, modest speeds, limited stop‐and‐
Sedate driving modest speeds limited stop and
go traffic: lower end of above ranges
– “Spirited”
Spirited driving, highway speeds, lots of stops driving highway speeds lots of stops
and competition green lights: high end of ranges
Acceleration, Top Speed & Handling
• AC induction vs series wound DC motors
– Power ratings
Power ratings
– Torque comparison
– RPM range (13,000 RPM vs
RPM range (13 000 RPM vs 5,000 RPM)
5 000 RPM)
– Gearing (top speed vs acceleration)
– Rear wheel drive and weight transfer
Rear wheel drive and weight transfer
– Battery and motor placement for low CG
– Autocross: weight distribution and corner weights
Autocross: weight distribution and corner weights
– Deceleration & braking, AC regen capability
Finances
• Realistic budget
– Identify and quantify all costs before starting
y
q
y
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– Materials, labor, custom fabrication services
• Operating costs
– Gas: 600 miles / 20mpg * $3.50/gal = $105/mo
– EV: 600 miles * 0.25 kWh/m * $0.10/kWh = $15/mo
• Maintenance
Maintenance costs: modest EV advantage
costs: modest EV advantage
• Repair costs for an EV conversion can wipe out an operating and maintenance cost advantage (make p
g
g (
sure that it doesn’t!)
Vehicle Platform
Recommended Skills
• Welding
– Battery
Battery frames/supports, motor mounts, heavy
frames/supports motor mounts heavy‐duty
duty brackets
• Sheet metal fabrication
– Battery boxes, light‐duty brackets
• Wiring
– LV control wiring, HV cables, fuses, terminal crimping, soldering, contactors, pot box (throttle control)
• Machining
M hi i
– Motor coupler, adapter plate
EV Components
EV Components
Matt Graham
Joule Injected Technologies
EV Components
• Battery pack
– Cells, modules, pack voltage, BMS, cooling, mechanical structure
• Motor
– AC/DC, conventional vs
AC/DC, conventional vs hub, coupling
hub, coupling
• Controller
– AC inverter, DC motor controllers, cooling
• Charger
h
– Conductive, OEM and EV conversion‐specific
• Misc. Components
Misc. Components
– DC‐DC converter, contactors, throttle input, fuses
Batteries
• Chemistry
– Energy and power density
E
d
d i
• Battery and Cell Format
– Capacity and packaging
• Safety & Durability
– Cooling, Battery Management System (BMS)
• Availability & other practical concerns
Availability & other practical concerns
– Shipping, customs, warranty, support
Battery Energy Density
Battery Gravimetric Power & Energy Density
Battery & Cell Format
• Exide Orbital ORB34DC‐36
– 12V marine deep‐cycle lead‐acid
12V
i d
l l d id
– Group 34 battery
– large format
– 50Ah (20 hour rate)
• 50Ah x 12V = 600Wh
• 600Wh x 25 = 15kWh
• 15kWh / 350Wh/mile = 43 mile range
15kWh / 350Wh/mile 43 mile range
– $150/ea x 25 = $3,750
Battery & Cell Format
• Kokam SLPB60460330
– 3.7V Li‐polymer
3 7V Li l
– 455 x 325 x 5.8mm cell
– Large format
– 70Ah
• 70Ah x 3.7V = 260Wh
• 260Wh x 100S = 26kWh x (100%) = 26kWh
• 26kWh / 0.20kWh/mile = 130 miles
26kWh / 0 20kWh/mile 130 miles
– $375/ea x 100 cells = $37,500 + shipping/customs
Battery & Cell Format
• Panasonic NCR18650B
–
–
–
–
3.6V consumer electronics Li
3
6V consumer electronics Li‐ion
ion 18mm dia. X 650 mm cylindrical cell
Small format
3.4Ah (2.9Ah in eBox)
• 2.9Ah x 3.6V = 10.4Wh
• 10.4Wh x 53P x 96S = 53kWh x (90%‐40%) = 26.5kWh
10 4Wh 53P 96S 53kWh (90% 40%) 26 5kWh
• 26.5kWh / 0.25kWh/mile = 106 miles
– Est. $350/kWh x 53kWh = $18,550 (ACP eBox)
$
/
$ ,
(
)
– Est. $250/kWh x 85kWh = $21,250 (Tesla Model S P85)
Battery & Cell Format
• CALB CA100FI
– 3.2V industrial LiFePO
3 2V i d
i l LiF PO4
– 142 x 67 x 219mm prismatic
– Large format , 7.5lbs each
– 100Ah (30A rate)
• 100Ah x 3.2V = 320Wh
• 320Wh x 75S = 24kWh
• 24kWh / 0.3kWh/mile = 80 miles
24kWh / 0 3kWh/mile 80 miles
– $145/ea x 75 = $10,875
Battery Safety & Durability
•
•
•
•
•
•
Calendar life
Cycle life based on DOD
Ambient heat
Active air or liquid cooling
Battery Management System (BMS)
Battery Management System (BMS)
Features to avoid pack discharge (bricking)
– Self discharge rate
Self discharge rate
• Features to avoid and contain catastrophic failure
Other Battery Considerations
•
•
•
•
Shipping costs, fees, customs
Shipping
costs fees customs
Warranty, battery/cell replacement
Interconnects
Maximum discharge rate
Motors
• AC Motors
– AC Propulsion
– UQM Technologies
– Brusa
• DC Motors
– Netgain WarP
– Advanced DC
Ad
d DC
• Hub motors, axial gap, PMDC
AC Motor Performance Curve
DC Motor Performance Curve
DC Motor Controllers
• Café Electric (Manzanita)
Café Electric (Manzanita)
– Z1K: 320kW max.
– Z2K: 640kW max
Z2K: 640kW max
– 156V, 300V & 348V versions
• EVNetics
EVN ti
– Soliton Jr: 150kW, 340V max.
– Soliton 1: 300kW, 340V max.
– Shiva: 1200kW, 425V max
Motor/Controller Wiring
Battery Chargers
• Manzanita Micro
Manzanita Micro
– PFC 20, 30, 40, 50, 75A
• Brusa
– NLG513: 200‐520VDC
– NLG514: 300‐720VDC
• Many others
– Need BMS interface
Nissan 240SX EV
Nissan 240SX EV
Matt Graham
Joule Injected Technologies
Performance Objectives: 240SX Range
Actual glider weights (6/23/04)
LF
RF
LR
RR
Total
With hood, hatch (no seats)
No hood, hatch, seats
With hood, hatch (no
console/interior/sunroof/seats)
404
384
377
362
464
436
469 1714
438 1620
366
334
436
442 1578
Material removed since 6/23/04
-1.5
-1.5
-1.5
-1.5
-6 (not really)
Added Components
Batteries
Battery box
Battery brackets and hold-downs
Motors (9 inch ADC)
Ch
Charger
(PFC
(PFC-20)
20)
Controller (Z2K)
Cabling (3/0)
Dash (original)
Carpet (original)
154
0
3
136
0
16
7
6
4
154
0
3
136
0
16
7
6
4
359
23
7
24
0
0
16
1
4
359 1025
23
45
7
20
24
320
18
18
0
31
16
45
1
13
4
16
Total EV weight
689
657
867
891 3105
Weight Ratios
Front
Rear
Left
Right
LF-RR Cross
RF-LR Cross
Front Left
F
f
Bias Bias
30% 50%
0% 50%
30% 50%
85% 50%
0%
0%
100% 50%
30% 50%
90% 50%
50% 50%
1347
Front/
43.4%
Back
1758
1557
Left/
50.1%
Right
1549
1581
50.9% Cross
1525
Performance Objectives: 240SX Acceleration
Data from Otmar's CaPope: 8" ADC motor
3155lbs
3.75:1 and
10 93inches
10.93inches
2.67:1
G Force Amps
Torque
Amps-Drag Torque
0.04
250
15
150
15
0.09
384
34
284
34
0.13
489
50
389
50
0 28
0.28
793
107
693
107
0.4
1009
153
909
153
0.66
1479
253
1379
253
0.72
1555
276
1455
276
0.68
1950
366
1800
366
Cu
urrent (Amps)
Weight
Ratio
Tire r
Torque versus Current
2000
1800
1600
1400
1200
1000
800
600
400
200
0
0 7837
y = 17.801x
17 801 0.7837
0
100
200
300
400
Torque (Ft-Lbs)
Horsepower and Torque Calculations: 9" WarP motors
Pack voltage
Current draw
Calculated battery voltage
Calculated pack voltage
Motor efficiency
300 V,
V no load
1700 A
7.55 V, under load
189 V, under load
0.8
344 HP
Torque per motor
Total torque delivered
864 Ft-Lbs
1728 Ft-Lbs
500
600
DC Motor and Controller Circuit
Performance Objectives: 240SX Top Speed
BFG g-Forge T/A Drag Radial Sizes
Size
Max
Max.
Tread
Tire
Rim
Meas.
Sect.
Tread
Overall
Revs
Service
Description
Load
Inflation
Depth
Weight
Width
Rim
Width
Width
Diam
Diam.
Per
Load Rating
235/60 R15
UTQG
0BC
1653 lbs.
Press.
44 psi
5/32"
26 lbs.
SL
275/50 R15
0BC
1830 lbs.
44 psi
5/32"
25 lbs.
Range
Width
6.5-8.5"
7"
7.5-9.5"
8.5"
9.5"
8"
26.1"
Mile
794
11.3"
10"
26.1"
791
SL
275/60 R15
0BC
2149 lbs.
lbs
44 psi
8/32"
8/32
33 lbs.
lbs
7 5-9
7.5
9.5
5"
8"
8
11 1"
11.1
8 9"
8.9
28"
28
743
SL
295/65 R15
0BC
2601 lbs.
44 psi
6/32"
36 lbs.
8-10"
8.5"
12.4"
8.5"
29.6"
699
SL
315/60 R15
0BC
2756 lbs.
44 psi
6/32"
25 lbs.
8.5-11"
9.5"
13.4"
11"
29.8"
695
SL
325/50 R15
0BC
2447 lbs.
44 psi
8/32"
8/32
35 lbs.
9-12"
9
12
10"
10
13"
13
27.9"
27.9
743
SL
345/55 R15
0BC
2910 lbs.
44 psi
6/32"
39 lbs.
10-12"
11"
14.6"
12"
29.8"
695
SL
255/50 R16
0BC
1687 lbs.
44 psi
6/32"
26 lbs.
7-9"
8"
10.3"
9.7"
26.1"
793
SL
275/40 R17
0BC
1433 lbs.
psi
44 p
6/32"
26 lbs.
9-11"
9.5"
11"
10.2"
25.7"
805
SL
315/35 R17
0BC
1433 lbs.
44 psi
6/32"
28 lbs.
11-12"
11"
12.4"
12"
25.6"
804
LL
Tires
Differential
255
50 R
4.08 :1
Width
Aspect ratio
Wheel Dia
255 mm
50
16 in
Side height
Tire diameter
5.02 in
26.04 in
Tire circum.
Max RPM
Speed
81.81 in
7000 RPM
133 MPH
Top Speed
Motor Speed
105 MPH
5530 RPM
Tires
Differential
275
60 R
4.08 :1
Width
Aspect ratio
Wheel Dia
275 mm
60
15 in
Side h
Sid
height
i ht
Tire diameter
6 50 in
6.50
i
27.99 in
Tire circum.
Max RPM
Speed
87.94 in
7000 RPM
143 MPH
Top Speed
Motor Speed
105 MPH
5144 RPM
16
15
Prepare for Conversion!
•Setup work area
•Remove hood/trunk
•Begin parts removal
•Engine
•Transmission?
•Fuel tank
•Fuel tank
Rear Battery Box
Rear Battery Box
Front Battery Box
Rear Seat Battery Box
Motor Setup
Motor Frame & Installation
Differential, Wheels and Tires
First Drive
Event Appearances
Motor Issues & Repairs
Final Form
Material Costs (Nissan 240SX example)
Item
Description
Qty
Cost/ea
Total
1
Glider vehicle
1
$350
$350
2
M
Motors
2
$1 800
$1,800
$3 600
$3,600
3
Motor controller
1
$4,950
$4,950
4
Batteries
25
$150
$3,750
5
Charger
1
$2,000
$2,000
6
BMS
25
$30
$750
7
DC‐DC converter
1
$500
$500
8
Driveshaft, motor coupler
1
$300
$300
9
Contactors
5
$200
$1,000
10
Misc. wiring and fuses
1
$450
$450
11
Misc. repairs and upgrades
1
$1,000
$1,000
Total
$18,650
Porsche 911 EV
Porsche 911 EV
Matt Graham
Joule Injected Technologies
Material Costs (Porsche 911 example)
Item
Description
Qty
Cost/ea
Total
1
Glider vehicle
1
$8,000
$8,000
2
M
Motor
& PEU (i
& PEU (inverter/charger/DC‐DC)
/ h
/DC DC)
1
$25 000
$25,000
$25 000
$25,000
3
Vehicle Management System (VMS)
1
$1,500
$1,500
4
Batteries & shipping (Korea)
100
$400
$40,000
5
BMS modules (4‐cells each)
25
$40
$2,000
6
Adapter plate
1
$450
$450
7
Porsche 915 transaxle, custom input shaft
1
$4,500
$4,500
8
PTC heater, controls, housing fabrication
1
$500
$500
9
Misc. wiring and fuses
1
$650
$650
10
Misc. repairs and upgrades
1
$17,500
$17,500
11
Labor
$20,000
Total
$120,100
Resources
• Electric Auto Association
Electric Auto Association
• National Electric Drag Racing Association
• EVAlbum.com
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