Download - Building an Electric Vehicle
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Building an Electric Vehicle:
Components and Construction
Part 1: Volkswagen Conversion
Part 2: Electric Go-Kart Race
Michael D. Kane, PhD(1) Associate Professor of Bioinformatics(2) University Faculty Scholar
(3) Chair of Graduate EducationDepartment of Computer and Information Technology
(4) Lead Genomic ScientistBindley Bioscience Center at Discovery Park
Purdue UniversityWest Lafayette, Indiana, USA
evw.tech.purdue.edu
http://bioinformatics.tech.purdue.edu/http://bioinformatics.tech.purdue.edu/ -
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1. range: function of energy density of the battery.
Compare gasoline @ 12,000 (theo.) / 2600 Wh/kgwith the lead-acid battery @ 175 (theo.) / 35 Wh/kg
2. time to refuel: charge 40 kWh in 5 minutes?
220 V 2200 A!!!
When you pump gasoline @ 20 /min,
your energy transfer rate is about 10 MW!(Hint: energy density of gasoline is 10 kWhth/.)
3. cost:
(a) light but safe means higher materials costs,
e.g., less steel, more aluminum; and higher processing costs,
e.g., fewer castings, more forgings...(b) to reduce load on the battery requires high efficiency appliances = costly
(c) low cycle lifebatteries priced @ $4,000 to $8,000
lasting about 2 years
Problems with EV propulsion
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Specific Energies of Battery Chemistries
(Wh/kg) (MJ/kg)
lead acid 35 0.13
NiCd 45 0.16
NaS 80 0.28
NiMH 90 0.32
Li ion 150 0.54gasoline 12,000 43
NOTE: 1 Wh/kg storage capacity equals about 1 mile driving range
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Specifications & Performance:
http://evw.tech.purdue.edu
Drive system: 72 volts (lead acid)Top Speed: 40 mph
Distance: 25 miles
Cost: $5,000 (total)
Vehicle: $1,500Batteries: $700
Electronics: $2,000
Batt Chargers: $500
Mechanical: $300
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Original VW Motor: 150 pounds (70 kg)55 hp
Conversion to Electric Motor: 70 pounds (30 kg)27 hp*200 pounds (90 kg) in batteries.
Conversion is +120 pounds (55 kg)
* The electric motor used in the conversion is rated at 15 hp (peak),but calculating horse-power in an electric motor is different than aninternal combustion engine.
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Contactor: A relay that closes the drive batteries
circuit (i.e. turns the vehicle on)
Throttle Box
Controller
Shunt
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Throttle and Controllers
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Configuration: 5 k ohm sealed pot without3-terminal
microswitch
Conection: 4 foot long, 2-wire unshielded, #22AWG cable
Stroke: Spring-returned lever arm drilled forvariable throw distances
Metal Parts: Corrosion-resistant stainless steel
Dimensions: 3.75" H X 4.00" W X 2.06" D
Configuration
:
5 k ohm sealed pot with 3-terminal microswitch
Connectons: Potentiometer: 4 ft. long, 2-wire unshielded,#22 AWG cableMicroswitch: Three 0.188" X 0.018" tabs
Stroke: Spring-returned lever arm drilled for variablethrow distances
Metal Parts: Corrosion-resistant stainless steel
Dimensions: 3.75" H X 4.00" W X 2.06" D
Throttle Controls
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Batteries : 6 x 12V lead-acid deep-cycle AND 1 x 12V for accessories
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Controller
Used in theVW conversion
Used in the EV
Go-Kart
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Controller (Programmable through Software)
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Electric Motor
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Electric Motor Mount
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Gauges
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TESLA$110,000
270 hp
EV-Bug$5,000
27 hp
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Tesla BatteryThe pack weighs 990 pounds, stores 56 kWh of electric energy, and delivers up to 215 kW of electric power,
375 volts. Battery cost is about $30,000
Each cell is 18mm in diameter by 65mm length, The small cell size enables efficient heat transfer, allows forprecise charge management, improves reliability, and extends battery pack life. Each cell is enclosed in a
steel case which effectively transfers heat away from the cell. The small size makes the cell essentially
isothermal, and its large surface area allows it to shed heat to the ambient environment.
Sixty-nine cells are wired in parallel to create bricks. Ninety-nine bricks are connected in series to create
sheets, and 11 sheets are inserted into the pack casing. In total, this creates a pack made up of 6,831 cells.
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Chassis
Motor mount added to rear
Battery mountsadded to sides
of cart.
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5 x 12V AGM Deep-cycle batteries in parallel
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Some carts used lithium iron phosphate batteries (3.3 V)
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Controller
Power Switches
Fuses
Contactor
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60V system with top speed of about 40 mph, endurance at about 40 laps.
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Technology and Innovation
On-board CameraGPS (speed)Lap-top to controllerBlue-tooth helmet
1) Remote desktop to cart PC2) Alter power settings during the race to optimize power/performance3) Video feed sent to Jumbotron (entertainment)4) Audio communications with driver
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