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ELECTRIC VEHICLE TECHNOLOGY

ELECTRIC VEHICLE TECHNOLOGY. David Brandt, P.E. The Basics:. EV: electric vehicle Are EV’s practical? Golf courses and airports have thought so for many years. But what about on the road? Are there EV’s among us? Yes, and not just in California!

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ELECTRIC VEHICLE TECHNOLOGY

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  1. ELECTRIC VEHICLE TECHNOLOGY David Brandt, P.E.

  2. The Basics: • EV: electric vehicle • Are EV’s practical? Golf courses and airports have thought so for many years. • But what about on the road? Are there EV’s among us? Yes, and not just in California! • Is there actually technology available to you and me to allow us to operate a practical EV? Yes!

  3. OEM EV’s (you may have heard of some of these): • GM EV1

  4. OEM EV’s: • Solectria Force

  5. OEM EV’s • Corbin Sparrow PTV

  6. Hobbyists? • The hobbyist says “If I can’t buy one, I’ll build my own… • Honda Civic

  7. More Hobbyist EV’s • My Escort

  8. More hobbyist EV’s • Ford Ranger

  9. Components • What is out there that you need to have to build an EV (besides batteries)? • Motor • Controller • Charger • DC/DC Converter • Heater • Instrumentation • Contactor(s) • Safety Equipment

  10. Motors • OEM’s: typically AC drive • Fail-safe design • Low initial torque, higher at speed • requires complicated electronics package • AC speed control (similar to industrial) • Inverter (convert DC to AC) • High voltage (240-350 VDC) • Bearings only mechanical maintenance item

  11. Motors • Hobbyist: typically brushed DC series wound • Motors are available and inexpensive • 100% torque at 0 RPM • Controllers are dirt cheap compared to AC • No inverter stage required • Lower voltage system (72-156 VDC) • Bearings and brushes are potential maintenance items (change brushes every 100,000 hours or so)

  12. Motors • “Advanced DC” 9” diameter motor • Others include GE, Prestolite

  13. Controllers • In General, Volts = Speed, Amps = Torque • Curtis • to 144 VDC, 500 Amps • Auburn Scientific • to 192 VDC, 1200 Amps • DCP • to 336 VDC, 600/1200 Amps • EVCL • “GODZILLA” to 336 VDC, 1200 Amps

  14. Controllers • All use PWM technology.

  15. Chargers • OEM: uses weird connectors like inductive “paddle” or AVCON “gas pump” nozzle. • Hobbyist: How about something everyone already has, like 120 VAC household outlets and 240 VAC dryer outlets? • Simple (voltage regulated) to complicated (computer controlled charging algorithms) • More advanced charging required for advanced batteries (AGM)

  16. DC/DC Converters • Uses PWM to step traction pack voltage down to 12V to run car accessories. • Common in electronics use • Not widely available in the voltages required

  17. Heater • Ceramic - Self-regulating temperature of about 180° F. • As temp. increases, resistance increases, decreasing power and stabilizing temp. • Therefore, more air across the element = more heat. • Typically 1500W. Can be stacked for more heat.

  18. Heater • The right type can be “harvested” from an AC ceramic heater.

  19. Instrumentation • Instrumentation can be as simple as an expanded scale voltmeter, but can be sophisticated, and include: • Traction Pack Voltmeter • Battery Current Ammeter • Motor Current Ammeter • Amp-hour/kWh meter (“E-Meter”)

  20. Contactors • BIG relays for switching traction pack

  21. Safety • Inertia switch to deactivate contactor(s) • same as is used to shut off fuel pumps in ICE cars • AGM batteries - no spillage • Service disconnects - BIG circuit breakers • Fuses, of course • Traction pack is electrically isolated from frame • 8 G crash load rating recommended for battery boxes

  22. Performance • Acceleration and speed • About the same as ICE • Ranges from “economy car” to “muscle car”. • DC motors great for drag racing • Current NEDRA record 8.801 seconds in the 1/4 mile by “Current Eliminator”

  23. Performance • tZero by AC Propulsion

  24. Performance - tZero • AC Propulsion's tzero out-accelerated a Ferrari F355, a new Corvette, and a Porsche Carrera 4 in a series of impromptu 1/8 mile drag races held on January 22, 2000 at Moffett Field in Mountain View, California, and at Calstart's northern facility at the former Alameda Naval Air Station.

  25. Performance - tZero • tZero mfg. By AC Propulsion versus Corvette

  26. Performance • Range - typically 30-60 miles • somewhat dependent on if you have a lead foot • great for commuting, which is where people use the most gas anyway. • Use an ice vehicle for long trips - the right tool for the right job. • Over 100 miles attainable with purpose-built EV’s or using advanced batteries

  27. Performance • John Wayland’s 120 mile range “Red Beastie”

  28. Performance • “Red Beastie’s” battery pack

  29. Emissions • Common claim is EV’s just move the pollution • Point taken, but power plant emissions are scrubbed to a point not possible on a vehicle.

  30. Emissions • Belfast electric bus project (4 year duration of monitoring)

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