Resume • FIRST Robotics • Solar Power Station • Solar Water Heater • Bike Plow • E-Bike • Workbench 1 .0 • Rain Barrels • Bike Generator • Volts wag on • TV Stand • Murphy Bed • Workbench 2.0 • Solar Death Ray Vehicle: 1 974 Volkswagen Beetle Voltage: 120 Volts DC Range: 1 6-26 Miles (25-42 KM) Speed: 70 MPH (112 KPH) Motor: 6.7" D&D ES-31 B Series DC Controller: Curtis 1 221 C Batteries: 1 DC-29, 1 2V Lead-Acid Cost: $6000 Road Map • History • Acronym Hell • Pros & Cons • Use Cases • EV Diagram • Conversion Kits • Open Source Hardware & Software • Tools • Conversion Car Wars (1835- 1920) EVs predate ICE autos by 50 years First to break 100 km/h (60 mph) barrier in 1989 EVs outsold ICE autos 1 to 1 The ICE Strikes Back (1910 - 2012) • Cheap oil • Electricity still limited and expensive • Growing rural population • 1914 Ford chooses gas- powered autos for motorized assembly line • 1 930 Electric tram networks bought out and dismantled by GM and Big Oil The Insurgence (1970 - 2003) • 1970's Air pollution concerns and OPEC embargo prompt manufacture of thousands of EVs • 1990s EVs produced in response to California Air Resources Board (CARB) mandates • 2003 CARB mandate repealed; EVs reposessed and crushed Return of the EV (1 970 - 201 2) • Tesla Roadster • Nissan Leaf Acron^ A- Amps AH - Amp Hours V- Volts w - Watts wH - Watt Hours wH/M - wH per Mile m Hell BEV- Battery Electric Vehicle NEV- Neighborhood EV PHEV- Plug-in Hybrid EV E-REV- Extended Range EV R-EEV- Range Extended EV Pros • More efficient (70-90% vs 1 5-30%) • Less Complex • Less Maintenance • Energy Independence • Sustainability • National Security • Environmental Cons • Batteries - Upfront costs ($35-200/mile of range) - Lower energy density • Weight • Range - Charge time Misconceptions • EVs are slow • The grid can't take it • Same pollution, moved to the plant • More resources/pollution • Lithium is too scarce Use Cases •NEV • Commuter • Business • Racer NEV • Golf Carts • Security/Maintenance • Grocery Getter • Inexpensive • Reduced regulations Commuter • ~80% of US commutes are under 40 miles • Typical cost <= $0.02 / mile • No power used sitting in traffic Business • Predictable routes • High mileage yields quick ROI • Low maintenence Race Car • Peak torque from RPM • Wider power band requires less shifting EV Diaaram rtmr-ifttac y® ^r© 6, ReJer id vehicle's shop manual, i-or connections fo Keyswilch, Check Engine Light, eic, 5- Heavy gauge wire ide-npred as ^g^g : should be ?.'£ awq, i. k-eiI'jhi gauge w^e? tUena'ed os i sfMpuld Us 10 AWQ mirwnum wllh a AWu pmfereA 3. Lighr gauge wire (denaied as \ should be 16 2. ReFer la dDcuTnenlahon lar inBlallalon and use dsla ,-5 about E-ach component le.g. PakTrakrl 1, High voltage cable and wire should have orange insulation, wrapped wilh arange electrical raoe or enclosed in argnge conduit. ND1E5: Conversion Kits Parts List Essentials • Donor • Batteries & Charger • Motor & Controller • Shaft Coupler, Adapter Plate • 12V Charger/DC-DC converter • Battery/Motor cables & connectors • Contactor(s) , Fuse(s) • Voltmeter, Ammeter, Shunt • Throttle signal Conditionals • Battery Management /Monitoring System (BMS) • Brake/Suspension Upgrades • SOC Gauge/monitor • Precharge circuits Recommended • Circuit Breaker/Emergency disconnect Temperature sensor(s) Tachometer Inertia switch 12V AUX Battery Motor/controller cooling Battery Box(es) / Insulation AH Counter Optionals • AC • Clutch • Heater • Low Rolling Resistance Tires • Power Steering • Solar Panel(s) Tools List Essentials • Shop manual for donor vehicle • 2+ ton trolley jack (high clearance preferred) • 2+ ton adjustable jack stands • Creeper • Sockets, Wrenches, Screwdrivers, Pliers • Angle Grinder • Handheld drill • Digital Volt Meter (DVM) • Wire strippers and crimpers • Cable cutters and crimper • Shop light • Rotary tool • Measuring Tapes Carry-On • Digital Volt Meter (DVM) • Jumper cable • Commonly used Sockets, Screwdrivers Recommended • Electrical Tape • Engine hoist or transmission jack • Clamp On Ammeter • Drill press • Air compressor • Rhino Ramps • Welding Equipment • Safety goggles or glasses • Latex (or similar) gloves • Soldering Iron • Zip Ties • Vise Optional • Workbench • Box cutter, Jigsaw, Cut-off saw, Hacksaw • Hammer, Pry Bar • Heat gun or torch Open Source • Controller • Charger • Instrumentation • Misc Open ReVolt projects *■ The Cougar EV Series 500 DC Motor Controller PCB S Mosfet Power PCB several versions are avalible on wiki. > The Cougar EV Series 1000 DC Motor Controller, Mosfet Power PCB, and Mosfet Driver PCB are avalible on wiki. > The preliminary EV SR Motor Controller PCB is on wiki. development is on going. > The preliminary EV AC Motor Controller PCB is on wiki. development is on going >The preliminary EV DC LCD Instrumentation PCB - Is now on wiki H! >The preliminary EV 6Kw DC Charger Controller PCB - Was added to the wiki HI s-The preliminary EV BMS Controller PCB - Was added to the wiki Hl * Planned Future Open ReVolt projects* >The EV IGBT Driver PCB - 8G2AA/LA5QQ Interface - Coming Soon III > The Uprising EV Series DC Motor Controller, and IGBT Driver PCB Coming Soon III EMW 10kW60A Open Source Charger EV Dashboard Conversion • Build Requirements • Explore the Possibilities • Find a Donor • De-ICE • Eliminate Waste • Motor • Controller • Charger • Batteries • Accessories • Hit the road! • Keep on Hacking Build Requirements • Identify motivations • Maximize your utility • How far? • How fast? • Budget? • Skills? • Reality check Explore the Possibilities EV Album EV ALBUM SEARCH YOUR EV EV RESOURCES CONTACT Doug Johnson's 1997 Ford Ranger XL X Updated: 06/22/2012 i : John W Mitchell's mi Saturn SC Updated: 06/23/2012 Martin Winlow's 200S Vectm VK-1 Updated: 06/13 '2012 in Bill Bates's 2001 Xevco Gizmo Updated: 0"? W 2012 ttiingstodo's 1991 Chevrolet S-10 Updated: 06/16/2012 Franav Bheda's 1972 Volkswagen Super Beetle Updated: 06/15/2012 Jarkko Santala's 19S7 Kawasaki GPX75 OR Updated: 07/OS/2012 Bmce Westlake's 2011 Think City Updated: 0S/1MA12 De-ICE • Remove the engine - Find buyer first! - Jack up 2-3 feet for bottom removal - Engine hoist for top removal • Drain and remove gas tank, radiator, starter, alternator, and other obsolete stuff Eliminate Waste • Less weight and less power draw = more range • May be able to remove or replace non- essentials - Swap Fix-A-Flat for spare tire - Convert power steering and brakes to manual Motor AC Regenerative braking Runs cooler Even less maintenance Cheaper Precharge Resistor • Small, but vital • Prevents current surge Charger Batteries Lead (Li Lower upfront cost Less sensitive No balancing necessary Easier to determine State of Charge (SOC) vs Lithium iPo4) Light-weight Long cycle life High power output Less maintenance Flat discharge curve Better cold weather performance To BMS, or not... • Active or passive monitoring • Some chemistries require BMS to maintain balance • Expensive and complicated • Potential Fire Hazard Balancing • No two cells are identical • Cells must be balanced to prevent damage • Balancing matches cells at either top or bottom • If overcharged, cell is damaged • If overdischarged, cell can be pushed to reversal and destroyed Accessories • Accessories may run off auxiliary driveshaft, or be powered separately Keep it Legal • Each state\country is different • Some require inspections • Some have strict requirements • Some do not allow many conversions • Some don't know what an EV is Hit the road! Sounds Great, But... • Perpetual Motion • Hydrogen • Supercapacitors • Hub Motors • DIY Hybrid • Solar Keep on Hacking WARNING: EV Conversions are a very addictive/obsessive hobby. The only way to 'finish' a conversion is to start another. Motor: $1200 Controller: $1000 Batteries: $800 Charger: $600 Adapter/Coupler: $500 Misc: $800 No longer being OPECXXON's Bitch: Priceless