driving to net zero with full performance
DESCRIPTION
Conversion of a 2003 BMW 325i to an electric vehicle with equal or better performance to the original gas powered specifications. By Bob Simpson of EVDrive.comTRANSCRIPT
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Driving to Net Zero with full performance
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Project goals
• Make an electric commuter for daily use, 40 mile round trip• Choose a fun and competent sports car platform• Meet or exceed original performance• Match the annual energy consumed with grid tied solar array
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Design philosophy
• Start with an excellent ICE design• Replace ICE drive with equal or greater
performance electric drive• Match the weight and its distribution• Gain confidence in battery cells from a
focused study and gathering real data
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Warm up projects
A fun battery test and development platformThis served as my BMS and cell packaging trainer
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University of Vermont hybrid electric race car
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Oregon State university Solar vehicle
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The chosen platform
2003 BMW 325i
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Commitment time
A young motor about to be pulled
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Brother Randy assisting with the removal
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The hanging ICE is destined for craigslist,The BMW is destined for transformation
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Motor and Inverter forms
High Tech modeling process:
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2040 cell Lithium Ion Battery packCells = A123 systems
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Motor comparison
Before and after
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New Drive package
Siemens AC induction motor mated with original 5 speed transmission
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Installing new drive
The motor installation is now a simple, one person job
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Inverter
Blue unit is a 700V 100kW drive (134 HP)150kW drive Inverter going in soon (200 HP)
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15kWhr Battery pack
This 700 Volt pack can deliver 1200 amps peak (10sec).Peak demand from 100kW drive system is 13% of that.
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Bottom of pack
Primarily for heating in winter, this plumbing uniformly distributes the heat.
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With plumbing secured
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Inside the pack
Modular format makes for easy access and low/safe voltages when handling
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Inside the pack
1 of 30 modules
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Inside the Battery pack
Plugging in the BMS slave boards
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Fun, Fast and efficient
The range is currently 45 miles, soon to be doubled
I have 6000 miles logged as of March 2011
The Result
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Waveform data of my drive to work
Yellow trace is pack VoltageBlue trace is pack Current
700V -->650V -->
0 A -->
Regen Current
Acceleration Current
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Power profile of my drive to work
This shows the true power being consumed over 20 mile commute
Average Freeway
Power (16kW)
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Other conversion benefits
• Full regenerative braking with high percentage energy capture
• One moving part in motor. No service other than tires and wiper blades
• Can be driven as original Manual transmission intended OR Automatic
• On-board charger can plug into any power source, just carry plug adaptors
• Daily commute costs are 4.7 times less than ICE equivalent at $3.50/gal
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Solar array preparations
Started with 70% exposure, need to meet or exceed 75% for grant money.We sent the logs to the local mill with proceeds helping fund the array.5.5kW Array soon to be installed will match annual BMW driving energy. The Blue roof is the planned site for the array, laying flat on surface.
The Christmas tree farm gone wild…
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For more detail on this and other projects
www.evdrive.com