The SWITCH Lab ™

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The SWITCH Lab ™

EV Conversion Review

7/2015

 Define driving requirements

 Define budget

 Research – www.evalbum.com

 Validate your plan – once you decide to go

 Select your glider

 Secure work space

 Follow these easy steps:

o Define needs o Determine new weight o Find a roller distribution o Weigh and measure Restore to your liking o Fix suspension o Review and recalculate o Order EV Parts o o Remove ICE o Install EV components o Measure motor mounts Document Design EV layout o o o TEST and TEST o Show off to friends!

 Removing

o Internal Combustion Engine – Deicing o Radiator o Muffler and exhaust o Gas Tank

 Optional

o Transmission o Spare tire o Other?

Refurbish non-ICE systems including brakes, steering, suspension, electrical, interior and exterior, then measure ride height

Measure:

oRide Height oWeight – preferably at each wheel oDistance from Face of motor mount to Flywheel

o Charger o Batteries o Controller o Potbox o Motor o Transmission / Drive Train o Main Contactor / relay o Instruments o Emergency disconnect o DC/DC converter

o Power Steering Pump o Power / Vacuum Brakes o Heater

The charger converts the AC from the grid or charging source to the on board power supply of the vehicle. Important Considerations:  Safety  Programmability  Voltage range of source  Size – match battery pack voltage  Efficiency Examples:  Brusa http://www.metricmind.com/charger.htm  ElCon PFC Charger http://www.elconchargers.com/products.html  Zivan http://www.zivanusa.com/NG3BatteryCharger.htm  Manzanita Micro http://www.manzanitamicro.com/index.php?page=shop.browse&category_id=14&option=com_virtuemart&Itemid=64&v mcchk=1&Itemid=64

Batteries are the fuel source for the vehicle.

Important Considerations (http://www.batteryuniversity.com/partone-3.htm)  Safety  Number of Cycles  Deep Cycle  C factor for charging and discharging  Power to Weight ratio  Match to motor requirements  Predictability  Availability  Cost

Examples: (see BatteryUniversity.com)

Controls the “fuel” going into the motor. Analogous to the carburetor of the ICE. Important Considerations: o Safety Features o Match to the Motor o Match to the Battery Pack o Programmability o Warranty / Vender support Examples:  Azure http://www.azuredynamics.com/products/force-drive/documents/AC24LS_DMOC445ProductSheet.pdf  Café Electric http://cafeelectric.com/shop/index.php?main_page=index&cPath=1  Curtis Alltrax http://www.alltraxinc.com/Products.html  DMOC0445 Zilla 1000 or 2000 Various Various

Interface from the throttle (gas pedal) to the controller to tell it how much “fuel” to give the motor.

Important Considerations:

o MUST match controller o Ease of installation o Safety o Redundant springs

The motor provides the power required to move the vehicle. Must match the motor’s performance parameters with the vehicle’s drive train. Important Considerations: o Safety – (sound familiar?) o Power o Efficiency o Match with battery pack voltage o Match with battery pack current o Match with Controller o Programmability o Maintenance Examples:  Azure http://www.azuredynamics.com/products/force-drive/documents/AC24LS_DMOC445ProductSheet.pdf  UQM http://www.uqm.com/pdfs/PowerPhase%2075%20(9.23.08).pdf  AC Propulsion http://www.acpropulsion.com/products.html  NetGain Warp http://www.go-ev.com/

The transmission/drive train is connected to the rotor of the electric motor and the vehicle wheels. If necessary gear reduction is added and the transmission may function in the same manner as the transmission of and ICE vehicle.

Important Considerations:

o Safety o Proper gear ratios  Acceleration  Top Speed

o Weight o Lubrication o Efficiency

The Main Contactor/Relay uses a little voltage to turn on a large switch to provide the completed circuit to power the controller.

Important Considerations:

o Safety o Must match Battery pack Voltage o Solid State o Must be able to “Break” total current of pack

Examples:  Cloud EV http://www.cloudelectric.com/category_s/4782.htm  Tyco 12 volt http://www.onlinecomponents.com/buy/PB-TYCO/KUHP11A5112/

Three key Instruments are:

o State of Charge – Fuel Gauge o Volt meter – total battery pack voltage o Ammeter – Measures amps being used at any point Important Considerations:

o Must match battery pack size o Readability Examples:  Various http://www.evparts.com/products/industrial-vehicle/metersetc/charge-fuel-levels---industrial-vehicle/  E-Vision http://www.metricmind.com/  Westach http://www.westach.com/  Various http://www.canev.com/KitsComp/Components/Fuel%20Guages.html

In the unlikely event of an electrical failure or vehicle crash it is important to have a high voltage disconnect switch within easy reach of the driver. Important Considerations: o Safety o Accessibility o Rated for proper voltage and current o Automatic

Examples:  Manual Automated http://relays.tycoelectronics.com/datasheets/ev200.pdf  Circuit Breaker Example

Actually a transformer that takes power from the traction battery pack and converts it for the low voltage (12 volt) systems in your vehicle. Important Considerations: o Safety o Match to needs in vehicle o Match to traction battery voltage o Placement – ventilation Examples:  Azure http://www.azuredynamics.com/products/force-drive/dc-dc-converters.htm  Brusa http://www.metricmind.com/  Generic http://www.thunderstruck-ev.com/index.php?dispatch=categories.view&category_id=40  Mes-Dea http://www.metricmind.com/

 Adding

 Electric Motor  Switches, relays & low voltage wiring  Batteries  Other EV Components  High Voltage Cabling  Conduit

 Others?

o Match Weight Distribution o Match Weight capacity  Curb Weight  Gross Vehicle Weight – cargo weight

o Avoid chassis modification to crumple zones o Avoid high voltage cable in passenger areas o Secure all components  What happens if the vehicle gets upside down?  Where does the water go if it rains?

o Design in quick and easy high voltage quick disconnect o Design in valet mode

o PHEV Plug in Hybrid Electric Vehicle

o BEV Battery Electric Vehicle

o ZEV Zero Emissions Vehicle

o NEV Neighborhood Electric Vehicle o EV Electric Vehicle

o Regenerative Braking Regenerative braking is used on hybrid gas/electric automobiles to recoup some of the energy lost during stopping. This energy is saved in a storage battery and used later to power the motor whenever the car is in electric mode. o Voltage Sag Voltage sags occur whenever a short circuit occurs whenever a short circuit occurs on either the utility transmission or distribution system that supplies your facility. o Amp hours Amp Hours, abbreviated Ah, is a term used to express the storage capacity of deep cycle batteries. This is the maximum sustained amperage drawn from a fully charged battery over a certain period of time to a point when the battery is at 100% DOD (depth of discharge). o Watt Hour Watt-hour (symbolized Wh) is a unit of energy equivalent to one watt (1W) of power expended for one hour (1h) of time.

o Watts The watt (abbreviated W) is the International System of Units’ (SI) standard unit of power (energy per unit time), the equivalent of one joule per second. o Horsepower The horsepower (hp) is a unit in the foot-pound-second (fps) or English system, sometimes used to express the rate at which mechanical energy is expended. It was originally defined as 550 foot-pounds per second (ft-lb/s). o Volts The volt (symbolized V) is the Standard International (SI) unit of electric potential or electromotive force. A potential of one volt appears across a resistance of one ohm when a current of one ampere flows through that resistance. o Motor Machine that converts other forms of energy into mechanical energy and so imparts motions.

Ohm’s Law E = I * R Voltage = Current * Resistance I = E / R or Current = Voltage / Resistance R = E / I or Resistance = Voltage / Current

Simple overview

1 watt = 1 volt X 1 ampere Watts 1 watt = 3.41 BTU are 746 watts = 1 horsepower Power!!!

Volt: Measure of electrical potential  Think of volts as pressure Ampere: Measure of current.

WATTS = Power

Watt = Volts X Current Killowatt = 1,000 watts = approximately 1.3 horsepower

Horsepower is used to measure the energy required by an electric motor to do work.

To calculate the horsepower of a motor when current and efficiency, and voltage are known, apply this formula:

HP = V x I x Eff 746 

HP = horsepower V = voltage I = current (amps) Eff. = efficiency

 How much horsepower does a 30KW electric motor have?

1 Horsepower = 746 watt 30,000watts / 746 = 40 horsepower

 BUT – we need to factor in efficiency