Upload
others
View
2
Download
0
Embed Size (px)
Citation preview
Electric FieroDavid Malloy
Fiero Project Goals• Battery Electric Car for commuting and in‐town errands
– Range: Daily commute is 12 miles (round trip) and flat– Speed: Need to keep up with traffic; top speed of 65 mph– Payload: 2 passengers with need for minimal trunk and storage space
• Safety, Construction Quality, and Appearance Important– Designed and constructed with reliability and safety in mind– Should not require maintenance but should be easy to maintain
• Did not want to push the technology envelope. Wanted:– a high probability of success– to copy examples of successful conversions– a ready source of parts and support
• Willing to build a prototype and to compromise (on certain things) if necessary
• Wanted to have fun, not to achieve perfection
Fiero Project Timeline
Fiero Decisions• Donor: 1988 Fiero
– Many successful conversions (e.g., evalbum.com)– Readily available and cheap parts– “Back to the future” styling
• 144V Kit and Design from EV America (www.ev‐america.com)– Excellent email support, DVD, Reference schematic– One stop shopping for: motor, controller, controller radiator plate,
adapter plate, charger, DC/DC converter, fuse, vacuum pump, contactors, Anderson connectors, Inertia Switch, welding cable,etc.
– Machine shop service for adapter plate (Clutchless design) • Major Features
– Advanced DC 9” motor / Curtis Controller– 12 * 30XHS Trojan Lead Acid Batteries (with “UT” terminals)– Zivan NG3 220V charger; Zivan NG1 DC/DC Convertor– Suspension upgrades would be required for added weight
Fiero Battery Boxes• “Erector Set” construction: cheap; easy to build and change.
Not optimized for space or weight
Motor Adapter• Direct Drive
– Single gear (e.g., Tesla)
• Clutched– When starting, put into gear and release clutch FIRST, then accelerate– When moving, shifts like a normal manual transmission– Provides additional failsafe under controller “stuck on” failure
• Clutchless– When starting, put into gear, then accelerate (like an automatic)– When moving, requires finesse to change gears without a clutch– Removes flywheel and pressure plate– Fiero uses the clutchless design
• See Pictures below– from Svein Medhus’ Ford Express conversion.
(http://www.geocities.com/CapeCanaveral/Lab/4429)
Clutchless Adapter
Clutchless Adapter (2)
Clutchless Adapter (3)
Clutchless Adapter (4)
Fiero Layout
Fiero Layout Notes• High Voltage / High Current
– 2/0 Welding cable, crimped lugs, Noalox, Anderson connectors
– Layout designed to keep “+” and “‐” physically separate– Conduit and “boxes” in tunnel (fuse, contactor, KSI, shunt)
• High Voltage / Low Current– Conduit in tunnel
• Contactor Control– in cabin against rear firewall
• Instrumentation– Jacketed cable used in cabin to bring high voltage to dash
• Weight Distribution– Most batteries are on the “outside” of the axles – not ideal
Fiero Front
Fiero Secondary Contactor Box
Fiero Rear
Fiero Rear (2)
Alternate Layouts
• from evalbum.com• “The good, the bad, and the ugly”• Concerns
– battery hold‐down construction– maintainability and access for battery watering– exposed high voltage– physical proximity of pack “‐” and pack “+”– distance of controller to motor– wiring neatness
Alternate Layout (1)
Alternate Layout (2)
Alternate Layout (3)
Alternate Layout (4)
Alternate Layout (5)
Fiero Wiring Diagram
Fiero Wiring Notes• Traction Pack Wiring (High Voltage / High Current)
– Dual contactor design, Fuse, SB350 Anderson connectors• High Voltage / Low Current
– Zivan NG3 – 220V/20A Onboard Charger– DC/DC convertor, KSI Relay, electric heater
• Contactor Control– Simple relay logic– Primary: ignition key in “run”, charger lockout, inertia switch– Secondary: adds high pedal lockout, potbox microswitch
• Instrumentation– Curtis “state of charge”– (relative) Ammeter– Charger and DC/DC converter status brought to in‐dash LEDs– Motor overtemp– PakTrakr (monitors pack voltage and individual batteries)
Fiero Contactor Control; etc
Fiero Instrumentation
PakTrakr
State of Charge
DC/DC Converter Status
Pack Charge Status
Ammeter
OverTemp
Other Notes• Charging
– Charges in ~4 hours (2 to 90%, 2 hours float)– 12V Supply to drive Status LEDs and Exhaust fans– Charging is done outside to vent hydrogen
• Vacuum Pump– Enabled when key is in “run”– Conventional installation with Vacuum reservior– Noisy (needs muffler)– Could use more reserve
• Electric Heater– Ceramic heater in place of original heater core– Wiring in conduit to relay on real firewall– Operated by original controls and fan– Only wired up ½ of the element: doesn’t work well
• Extras– “Reddy Kilowatt” badging– Beep on Backup– LED lighting– IPOD mini sound system
Results• Success !
– Daily driver; almost 2000 miles logged since January – 0‐30mph; performance just fine; keeps up with traffic.– Reliable; only maintenance is once a month watering– Quiet and no hydrocarbon smells– Cool Looking– Project cost ~12K
• Areas for Improvement– Range only about 18‐20 miles– Handling is “heavy”– 30‐60mph performance not so great– Want a lighter donor, lithium batteries, more attention to weight and
weight distribution– “Funny noises”: contactor and vacuum pump
Component ScorecardComponent Now Major Dislikes
Batteries Trojan 30XHS – SLA Capacity, weight, weight distribution, safety
Battery Boxes Bolted Weight, durability
Drive System ADC 9” / Curtis 1231C Whistle when starting; No regenerationNo Integrated contactor control
Adapter Design Clutchless
Pack Charger Zivan NG3 ‐ Onboard 220V No 110V, not sealed, no BMS integration
DC/DC Converter Zivan NG1 Not sealed
Heater Ceramic Not functional
Vacuum Pump Gast/vacuum switch/reservior Noisy, not integrated
Contactors Albright Noisy, not sealed
Instrumentation PakTrakr, LEDs, ammeter High voltage in cabin, no data logging
Safety 2 contactors + fuse No Emergency Disconnect
Wish List for Next Time• Want
– More Range– Better Performance and Handling– Better aesthetics (silent operation, nicer donor car)– Opportunity charging– Better instrumentation (data logging, CAN bus, better BMS)– Working heater
• More attention to Weight and Weight Distribution– Lighter Donor– Aluminum Battery Boxes– Lithium Pack
• AC motor and regeneration• More attention to durability and maintainability
– Sealed components
Make/Model Year Weight CdA sq m Notes
Lotus Elan 62‐73 1500 .57 Nice examples >20K$
Fiat 850 Spider 65 1620
Triumph Spitfire 62‐80 1800
MGB 62‐70 2030 .66
Porsche 914 69‐76 2085 .60
Triumph TR4 61‐65 2130
Datsun 2000 67‐70 2135
Fiat 124 Spider 69‐85 2100‐2355 Many, <10K$
Porsche 911 S 69‐74 2249‐2381
Alfa Romeo Spider Veloce 69 2293
Mazda RX‐7 78‐85 2400 .55
Triumph TR6 69‐76 2491
Pontiac Fiero 84‐88 2700 .63
Classic 2 Seaters
Modern 2 Seaters
Make/Model Year Weight CdA sq m Notes
Lotus Elise S 02‐ 1896
Mazda MX‐5/Miata 90‐98 2100 Kits available for adapter plates and battery boxes
Honda del Sol 93‐97 2296
Toyota MR2 (Mk1) 00‐07 2300
Mazda MX‐5/Miata 99‐05 2350 More safety features
Tesla 08‐ 2723
Acura NSX 90‐05 2950
Make/Model Year Weight CdASq m
Notes
Fiat 500L 72 1190
Austin Mini Cooper 65 1411
Renault Dauphine 56‐67 1433
Volkswagen Beetle 64 1629
Honda Insight 00‐06 1850 .49
Yaris 2293
Toyota Corolla 66 2530
Ford Mustang 64‐73 2570 .44
Ford Focus 00 2621
Honda Civic 72 2628
Mitsubishi Lancer 73 2745
Saturn Ion 03 2752
Mazda 3 04 2780
VW Golf
Sedans