how to [and not to] build an electric · pdf fileelectric motorcycle zachary rubin. why build...
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How to [and not to] Build an Electric Motorcycle
Zachary Rubin
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Why Build an EV?
Gas is Costly Electricity is win EcoTard Coolness factor Even more for
motorcycles
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My Conversion
1980 Suzuki GS450 Sepex motor 72-80v, 450A
Controller 12v (6x) 35Ah SLA
batteries 7A, 4 stage 'smart'
SLA chargers (6x)
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What to expect
Fun and Rewarding Budget dependent Less range and top
end Comparable
acceleration Long term cost
savings
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On to the Good Stuff! System Overview
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Traction Motor
BLDC/PMAC
AC Induction
Series wound
SepEx
Hub motor
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Controller
Specific to motor type Features!
CAN bus USB programmable 'Programmable' IO 'ignition' key switch Contactor Control Throttle Regen Control LV supply
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Contactor
BIG mechanical relay Disconnect batteries
when not in use Reversing NOT necessarily HV
safe... Precharge resistor
Traditional disconnect not a bad idea
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Throttle
Magura twist grip Potentiometer in
convienent form factor
2nd 'clutch' type for regen
Other form factors available
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Batteries: jargon
SoC - State of Charge
DoD – Depth of Discharge
BMS – Battery Management System
Energy Density Specific Energy C (rate) - Capacity
Peukert effect SLA – Sealed Lead
Acid NiMH/NiCd (not so
important) Li-ion, LiPoly, LiFe,
LiPo, LiFePO4, LiCoO2, LiNiMnCoO2, LiCo nano
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Batteries: packs
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Batteries: Charge and Balance
Off the shelf charger/balancer
Active/Passive
Individual chargers
Match charger and Chemistry
Charge Rate On/off board
Image from ACI chargers
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Batteries: Connectivity
Fuse + Disconnect Mind Temp+Vibration Protective circuitry Inductive Paddle Direct contact Mains
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Other Electronics
72->12v DC-DC converter
Arduino indicator ctrl SoC Estimator Head Unit
CAN Batt/Controller data
PlugShare+GPS Speedo Security
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Lessons Learned (aka FAIL)
Chain clearance Battery Bottleneck Contactor Pitting [not so] smart
chargers Shaft key Design for
modification
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End. Questions?
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links
http://www.elmoto.net/ http://cafeelectric.com/ http://www.acichargers.com/ http://www.electricmotorsport.com/ http://www.sevcon.com/ http://batteryuniversity.com/