Building an Electric Vehicle:Design Considerations

Throttle and Controllers

Configuration:  5 k ohm sealed pot without 3-terminal microswitch

Conection:   4 foot long, 2-wire unshielded, #22 AWG cable

Stroke:   Spring-returned lever arm drilled for variable 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 variable throw distances

Metal Parts:  Corrosion-resistant stainless steel

Dimensions:    

3.75" H X 4.00" W X 2.06" D

Throttle Controls

Included Controller

Amps Voltage range Peak Horse Power

RPM Kit price (motor and controller)

Alltrax DCX-300

300 A 24V - 48V 13 hp 3000 $1050

Alltrax DCX -400

400 A 24V - 48V 15 hp 3000 $1150

Alltrax DCX -500

500 A 24V - 48V 16 hp 3000 $1250

Alltrax DCX-600

600 A 24V - 48V 17 hp 3000 $1425

Sevcon PowerPak

425 A 60V - 84V 25 hp 4500 $1525

Controller

Controller (Programmable through Software)

Electric Motor

D&D SepEx motor -Separately Excited- Sepex motors are almost identical to traditional Series motors except for the way their field is wired and controlled. Unlike the Series motor who's armature and field windings are wired together in series, the SepEx motors field and armature windings are excited separately by special SepEx controllers that have wire leads to both the armature and the field. Separate control of the armature and field creates distinct advantages over a standard series wound motor, notably adjustable regenerative braking, higher rpm, longer power band, higher efficiency, and easy reversing.

A greater rpm range and higher top speed . Field weakening towards the SepEx motors top end allows for higher motor rpm which allows for a higher top speed on your vehicle.

Higher motor efficiently. The SepEx motor is more efficient than a series motor due to its more efficient use of the field.

Easy reversing. With a push of a button or flip of a switch The SepEx controller can easily change the direction of the motor by reversing the field.. making cumbersome, out-dated reversing contactors a thing of the past

Regenerative motor Braking This is one of my favorite features of the SepEx motor. The Sepex controllers can create very efficient and smooth regenerative braking on the motor by reversing the direction of the field and varying the reversed field's current. This essentially turns the motor into a generator while the vehicle is braking or coasting, and puts that generated power back into the batteries. The sensation feels like compression braking on an Internal Combustion Engine vehicle except smoother. Regenerative braking definitely makes an Electric motorcycle feel more like a motorcycle. Other benefits of regen braking, besides recharging the battery packand increasing range (if that wasn't enough), is that it makes steep hill descents easier to manage, as well as saving on brake pads and parts.

These motors are only sold as motor and controller kits, with matching tuned Sepex controllers from, either Alltrax Inc (USA) or Sevcon (England). D&D Sepex motor (USA) Dia. 6.7"........Length 11"........Weight 56Lbs.........Shaft dia. 7/8" W/ 3/16 Keyway

Electric Motor Mount

Batteries

Battery Charger

Braking

Gauges

Safety & Communications

Discussion PointsPOWER MANAGEMENT

Battery Charging

Regenerative Systems

Solar Cells

Gauges and Communications

VOIP

Video

Sensors

Display (Driver & Crew)

POWER SYSTEMS

Battery Types

Volts & Amps & HP

TRANSMISSION

Belts or Chains

SAFETY SYSTEMS

Gear

Switches

Power Indicators

Gel Batteries