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This project involves optimizing a 1974 VW Electric Bug to improve its speed, torque, and range while meeting customer needs. Through various concepts, including adding batteries and upgrading the motor and controller, we developed a range of configurations. Key concepts explored include the addition of six deep-cycle batteries, a new AC motor setup, and innovative battery configurations, all aimed at maximizing performance metrics. Our decision matrix led us to conclude that combining battery optimization with advanced motor controls will yield the best performance results.
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Optimization of a 1974 VW Electric Bug Group 16 Michael Boyle Michael LaBeach Andrew Magaletti Rabei Rabei
Customer • Andrew Park • Owner of the car • Graduate Student at Florida State University • Dr. Hollis
What is the Problem? • Hills • Speed • Range • Lights • Interior
Scope and Customer Needs • Increase Torque • Increase Speed • Increase Range • Distribute Weight
Concept 1 – Add 6 Batteries • Components Needed: • 6 12V Deep Cycle Batteries • 24V Field Battery Pack • Battery Configuration: Series/Parallel • Estimated Top Speed: 70mph • Estimated Range: 55 miles • Cost: $530
Concept 2 – New Motor • Components Needed: • AC Motor • DC to AC inverter • Battery Configuration: Series • Estimated Top Speed: 50mph • Estimated Range: 45 miles • Cost: $4000
Concept 3 – New controller • Components Needed: • Controller • 10 Batteries • Battery Configuration: Series/Parallel • Estimated Top Speed: 65 mph • Estimated Range: 70 miles • Cost: $2200
Concept 4 – Lower Voltage Batteries • Components Needed: • 9 8V Deep Cycle Batteries • 24V Field Battery Pack • Battery Configuration: Series • Estimated Top Speed: 70mph • Estimated Range: 35 miles • Cost: $840
Concept 5 • Components Needed: • Advanced DC L91-4003 Series Motor • Kelly Controls KDH09500A • (10) 12V Deep Cycle Batteries • Battery Configuration: Series/Parallel • Estimated Top Speed: 80mph • Estimated Range: 70 miles • Hills? - Yes • Cost: $2506.86
Optimum Design • Concept 1 • Why?
Conclusion • Boundaries Overcome • Battery connection • Pre-winding the magnetic field of the motor • Series vs. Shunt vs. AC
Future Plans • Regenerative Braking • LED Lights • Battery Cage • Rob Matthies • Conversion Manual