The problem of creating an alternative transport in Ukraine is being solved not only by scientists (hybrid "Sobol", "AC" No. 7'2009). Homemade electric car"Electra-2", the creation of the Kiev master Mikhalych, was created in an ordinary garage cooperative, where our acquaintance took place.
The problem of creating an alternative transport in Ukraine is being solved not only by scientists (hybrid "Sobol", "AC" No. 7'2009). Homemade electric car"Electra-2", the creation of the Kiev master Mikhalych, was created in an ordinary garage cooperative, where our acquaintance took place.
The attentive reader will ask why "Electra-2"? The first creation of Valentin Mikhailovich Herbstein (among colleagues - Mikhalych) appeared in 1992. It was a two-seater convertible with a convertible roof, assembled on a welded frame and sheathed with sheet iron. A self-made electric car at a speed of 30-35 km / h could travel up to 100 km and easily developed its maximum 60 km / h.
But progress does not stand still and the desire to create from the enthusiast-craftsman, despite the 15-year break, did not disappear. And although work on "Electra-2" has not yet been completed, we managed to ride with a breeze in a silent electric car.
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The steering mechanism from the SZD motorized carriage is rack and pinion. It is lighter and more compact than a worm gear, has a lower gear ratio and therefore is more convenient for a high-speed car. |
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an electric car from Volyn. |
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With the world on a string ...
The frame of the homemade electric car is welded from rectangular pipes and sheathed with stainless steel sheets. The choice of material for cladding is not accidental. Although stainless steel is more expensive than ordinary steel, it is stronger, besides, it is not afraid of corrosion and is better connected by electric spot welding. The thickness of the sheathing along the sides and at the bottom is 0.8 mm, in some unloaded areas - 0.5 mm.
The front axle, together with the steering gear, is borrowed from the SZD motorized carriage, better known among the people as the "invalid". This choice is due to its lightness, and in terms of strength, it can give odds to many modern ones.
V rear axle assemblies from ZAZ-968 and LuAZ-969 were assembled. Levers rear suspension taken from "Zaporozhets". For the parallelism of the suspension travel, they had to be slightly altered. And in order not to rust, Mikhalych welded them with a continuous seam, pouring inside a glass of nigrol.
Hubs and semi-axles are Luazovsky. The main gear (also from Volyn) is connected to an electric motor through a cardan shaft and a clutch. And the ability to lock the differential improves the vehicle's cross-country ability. As the saying goes, every thread ... and the chassis is ready.
Despite the fact that all bodywork is carried out using a gas torch, spot welding and hand tools (hammer, scissors), the stainless steel shell turned out to be quite neat and symmetrical.
Homemade electric car and its filling
As power unit a 15 kW Advanced electric motor with a peak power of 60 kW was taken. It is controlled by a pulse-width modulator (PWM, an electrical circuit based on electronic keys, designed to optimize the process of transferring power from a battery to an electric motor) Curtis. These components, together with the Zivan "charger" (3 kW), are included in the so-called kit for converting conveyor vehicles into electric vehicles, which has been successfully sold in the USA and Europe for several years.
The role of the battery is played by 10 Trojan Minn Kota traction lead-acid batteries (130 a / h each), which are rather neatly placed in the luggage compartment and the engine compartment of the convertible.
When driving in city, the battery charge is enough for 100 km of run, and maximum speed electric car - 150 km / h.
To extend the life of the batteries, the author of the project changed the classic way of connecting the battery to the electric motor. Two sections (each with 5 batteries) are connected in parallel - a voltage of 60 V is supplied to the controller during acceleration and driving.For high speeds and loads, a toggle switch on the instrument panel switches the battery to 120 volts ( serial connection sections). This complication made it possible to save it from impulse high-frequency loads that are harmful to the service life, replacing them with an almost constant discharge current.
Homemade electric car: electric brake
And, of course, recuperation. An electric vehicle without the ability to charge the battery during braking is considered defective. But, according to the designer himself, the amount of energy returned as a result of recuperation to the battery is scanty compared to that spent on movement. The role of an electric brake (albeit ineffective) in "Electra-2" is performed by a generator from Lada 110, which is installed directly on the traction motor and is connected to it with standard pulleys.
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Test drive a homemade electric car
In theory, when driving at speeds up to 60 km / h, the battery charge is enough for 100 km of run. You can go faster (the maximum speed of the Electra-2 is 150 km / h), but this time at the expense of a decrease in mileage. The battery is charged from a household outlet, it takes about six hours to fully charge, or three hryvnias, if you take it in monetary terms.
The salon of the silver handsome man was not as impressive as its appearance (old shabby seats, wiring hanging from all sides), although the devices are installed quite conveniently. The visibility is quite acceptable. No ignition key, one flick of the toggle switch and control lamp on the instrument panel gives the go-ahead. You don't need to make any special efforts: pedal - gas, pedal - brake and turn the steering wheel. Reverse- please, for this, the reverse lever is located in the usual place for the gearbox lever.
Homemade electric car- the car is obedient and completely silent, if you do not take into account the slight knock of the still unfinished roof. It was not possible to get a jerk from a standstill, although the acceleration dynamics are quite acceptable and very much felt when working with the accelerator pedal. The reason for such obedience is the energy-saving settings of the controller, which, during acceleration, supplies a low voltage (up to 50 V) to the electric motor.
As for 150 km / h, we failed to confirm in practice the maximum speed of the Electra-2 declared by the author (due to road and weather conditions). Although, judging by the dynamics, which did not decrease when driving over 60 km / h, but only increased, the ability of this electric car to drive fast is beyond doubt. It will be possible to say for sure in the summer, when the electric car is ready and will be registered with the MREO.
The author of the project
When asked why I created a home-made electric car "Electra-2", I have several answers. First, I want to show the public that an electric car today can become vehicle for city driving. Secondly, to demonstrate to the heads of enterprises what exactly needs to be produced, what will be in demand, and not lying in warehouses. And thirdly, to prove to his sons and others' sons that technical creativity can be more exciting than computer games. Unfortunately, any undertaking is futile if it does not have the support of the state, officials and the media.
Vladislav Osadchiy
Photo by Andrey Yatsulyak
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(Based on materials provided by the author)Article: & nbsp Tokmakov N.M.
It will be about the business of life of a person keen on ecological transport, a Soviet officer, Russian Colonel Valery Vasilyevich Boznoskov.
Valery Vasilyevich, having spent his entire military part of his life at training grounds and in hot spots of Africa and the Middle East, after retiring, gave himself up to his favorite hobby - ecological transport. Namely, electric vehicles, the most promising alternative for the near future. He actively participates in Internet forums on electric vehicles, creates his own website and forum, making a lot of efforts to support his lively work. Valery Vasilyevich aims to show that not only concerns can build an electric car, but also an ordinary person is able to make an electric car for himself, register and use it on a general basis. To popularize the idea, several samples of electric transport were created, a Center was created ecological transport, work is underway in the Moscow government to create a Moscow serial electric car. In recent years, several copies of electrical engineering have been created, namely the electric Monza, the Porter truck, the electric trike, the Suzuki electric motorcycle, the electric buggy, the SMART car is undergoing transformation.
And now directly about the products:
Monza is one of the first transformers - the conversion of the 1981 Opel Monza into an electric car. For the electrification of the car, the experience of Western electric vehicles was used: a set of a collector electric motor manufactured by Advanced DC Motors (USA) with a supply voltage of 120V and a controller delivered from the USA. The electric motor is connected directly to the gearbox via the adapter plate. Alteration of the car took about six months. The weight of the electric car turned out to be 1500 kilograms.
The first result was successful and inspired the author to continue his work. The electric car has good dynamics and handling. On the Internet you can find videos with demonstration trips of an electric car. Acceleration time to 100 km / h 14 seconds, mileage on one charge without stops 60 km, daily mileage (with stops) 75 km, maximum speed 120 km / h.
The first photo gives an idea of how it has changed dashboard(torpedo) former car... It added a 120 volt voltmeter and an ammeter. Further, we can see the switching equipment that is used in an electric vehicle: a contactor, a shunt, a rheostat for regulating engine speed, a 1500 amp automatic machine for protection against overloads and short circuits.
In one of the following photos we see a traction motor with a peak power of 60 kW, size according to the manufacturer's classification 8 "(eight inches). And the photo closes the gallery. charger Zivan 132 volts with a charging current of 3 kW.
Due to the significant interest in the electric car, it was overhauled, the body was repainted, the interior upholstery was over-tightened, and decorative elements of the body were replaced.
Electro-MONZA is one of two electric vehicles officially registered with the traffic police and has a license plate. The video can be obtained from the RUTUBE resource: http://rutube.ru/tracks/205904.html?v=4c673a528749dcdcb942c5382d975a1d
Alteration of the car took only 3 months, taking into account the waiting for the ordered parts and batteries. The work was carried out by two people. The truck is not subject to restrictions for trucks, besides it has benefits as an electrified vehicle.
The electric truck has more better dynamics than with the native turbodiesel. The charging time for batteries with a storage capacity of 25 kilowatts is 6-8 hours.
In August of this year (2009), registration documents were received and now an electric truck can legally be a road user.
During the registration process, a certain change in the order of certification at NAMI was discovered. Now it is necessary to present the analogs of the vehicle. The fact is that during the registration of "GAZEL-Electro" the "GAZ" company certified some units, for example, motors and controllers Azure Dynamics / Solectria, a vacuum cleaner GAST, ThunderSky batteries and some others. It is easier for an applicant for certification to go through the procedure if he uses these units. It will be more difficult to register with unknown Chinese.
The ride is a biker's dream. Just what you need for an imposing trip around your hometown, village. Surprise people, show yourself.
The electric motorcycle was assembled for recreational purposes and fully justified the expectations placed on it.
Received specifications electric motorcycle:
Characteristics: Speed - up to 80 km / h, mileage - 50 km,
Fast charge time - 1 hour,
Weight - 160 kg, battery Leoch, 55 A * h, - three pieces.
Recuperation, reverse.
Etek motor, three-phase, powered by direct current, 4/9 kW.
Controller - Millipack, 300 A, 36 volts.
Converter 36-72 V to 14 V.
The cost of the alteration is 60,000 rubles.
The electric buggy is an unfinished project. But there is already something to show.
Specifications:
Speed 50 km / h, cruising range 40 km. Reverse is realized by electric reverse.
Weight 280 kg.
Motor sequential excitation Raymond, USA, 13/35 kW., Altrax controller, 72 V, 450 A.
Six batteries LEOCH, 75 A * h.
Reverse contactors, England. The original was equipped with an IZH engine. The drive is carried out chain drive with 15 teeth driven sprocket, 50 teeth driven and 15.85 mm pitch chain. The drive is transmitted to wheels with large tread from sports buggies. Steering as is customary on a buggy, a pendulum design. The wiring is done with a 70 sq. Mm cable, the reverse, as already mentioned, is on the contactors. The circuit breaker is located near the driver between the 3rd and 4th batteries. The total weight of the batteries is 150 kg. The first test drives showed the need to apply additional cooling to the engine. It is planned to install computer coolers near each of the four windows of the electric motor. In the creative biography of Valery Vasilyevich, this is not the first buggy. One of the past copies is shown below in the photo. It has crazy dynamics and speed for its class of vehicles.
The year 2010 was laid new project- converting a SWIFT car into an electric car.
Specifications:
Speed 50 km / h, cruising range 60-80 km km. Reverse is realized by the controller.
Weight 725 from the original, after removing unnecessary nodes 575 kg. The final weight has not yet been determined.
Serial excitation motor 48 volts, 150 amps, Altrax controller, 48 volts, 450 A.
Eight six-volt stationary batteries with a capacity of 180 A * h weighing 30 kg each from France. Converter from Taiwan. The charger is European, smart, impulse, 56 V, 45 A.
Electromobile numbers are already available.
Reverse contactors, England. The final decision was made to install a golfcar motor with 5 kW of rated power on the car. The voltage on board is still 48 volts. An end flange with a bearing for the rotor shaft was machined and installed on the motor. A transitional elastic coupling with slots at the ends and a transitional plate-washer are made. The motor is articulated with a box. Installed on the machine.
The 220 volt input was made from the place of the fuel filler neck. Through the usual connector. Through the fuses, they brought it under the hood, where the 25 A charger is located (on the left). When using a full-fledged native gearbox and a 5-kilowatt electric motor, the acceleration dynamics is about the same as that of a donor with an internal combustion engine of 1000 cubes. There is no voltage drop. On the Altrax controller, the limitation of 70% of the starting and swing currents is calibrated.
Gear shifting is easy, without jerks and side sounds. The brakes require some effort despite the curb weight of the car being 900 kg + 100 kg of the driver. In general, the dynamics and handling of the car are good.
Before installing on a car, I changed the oil in the gearbox. Filled with an automatic machine with an SAE viscosity of 50 units. It is assumed that the efficiency of the Suzuki light transmission is at least 94-95%. The losses are insignificant. Much less than due to the operation of the electric motor outside the rated speed in case of refusal from the full transmission.
The clutch is not installed on all cars. Extra node. Only reducing the dynamics of acceleration. The energy of the rotating rotor of the electric motor is negligible compared to the state of rest of the car.
After a five-minute intensive drive, the controller on the radiator and the electric motor only slightly warmed up. As a positive result of moderate electrical loads. Through the use of the checkpoint. It is possible to further increase the acceleration dynamics by removing all restrictions from the controller. Wiring is done with 70 sq. Mm cable. The idea is wandering around to install 8 Minn-Kota batteries, 100 A * h, 12 V. They are close in size to the current ones. They will weigh 185 kg instead of 240 kg. And the energy consumption will provide about 10 kWh. Now theoretically 9 kWh, in practice - less. They are not new.
When placing four 105 Ah and four 120 Ah Deka batteries on the machine, you can get almost 11 kWh of energy with a battery weight of only 205 kg. That will provide a mileage on a single charge of at least 100 km at a speed of 60 km / h. With a battery price of only 50,000. And a resource of up to 700 cycles at 60% discharge.
On the brakes. Probably will be installed vacuum amplifier... There's a meaning. The kit is available.
The interior will be heated. It is planned to stick a couple of dozen 25 W ceramic resistors on the stove radiator. Other options are possible.
Calculations of the cost of components:
1. The cost of the motor was $ 500, the used controller - about the same.
2. In case of refusal from the checkpoint, an electric motor with Mcr at least 4 times larger would be required. And the corresponding converter to it. At a total price of at least $ 4,500. Weighing over 50 kg. There and then there would be a need to purchase more powerful batteries. Install a different contactor. And much more.
In conclusion, it is not superfluous to say that a cheap electric car satisfying most of the requirements for a car is possible. Valery Vasilievich came to this conclusion from the following considerations:
1. Electric vehicle in budget option can travel up to 100 km per day.
2. The main route of most people living and working in the city from home to work and back does not exceed 50-60 kilometers, and this is the main daily route. And indeed, if you think about it, it becomes clear that this main route eats up a lot of money on gas, despite the fact that half of the travel time people are stuck in traffic. At the same time, gasoline continues to be consumed, and the electric car at this moment stands without consuming a single watt of energy. In addition, the property of batteries is such that when they are idle, they self-recharge a little. So that for an electric car it is beneficial in double.
3. An electric car can delight the owner with the low cost of operation, dynamism, the ability to move around in places where it is forbidden to find a smokehouse. Riding takes place in complete silence.
4. The process of electrification of transport is underway in the world. Car manufacturers are developing serial electric vehicles. In the coming years, electric vehicles will begin to roll off the conveyors in a massive flow.
Note: This spring (2009), at a government meeting, Moscow Mayor Yuri Luzhkov said that it was necessary to transfer intracity transport to electric traction. In his opinion, electric vehicles will have a beneficial effect on the ecology of the city, and this work is very important. It is planned to open gas stations for electric vehicles using preferential night electricity rates, to give priority to electric vehicles in access to the city center, and parking benefits.
The current measures are still silent on the fate of ecological transport.
Building an electric car is a great alternative to a car with gasoline engine. Modern technologies allow to find new ways to solve the problems associated with the cost of vehicle fuel.
Spending money only on the constituent elements of the future electric car, in the future, you can perfectly save on fuel.
In addition, electric motors are environmentally friendly unlike conventional engines which, when processing gasoline, emit carbon dioxide.
It is worth noting that almost every car company already produces electric cars or hybrid cars. For example, from the company of the same name.
But the price of such environmentally friendly vehicles remains inaccessible to many motorists, so the issue of creating an electric car with their own hands, especially for the CIS countries, is still very relevant.
We create an electric car
To create an electric car with your own hands, you need to purchase:
- Base car model;
- Electrical engine;
- Batteries, cases for them and charging;
- Gas electric pedal, as well as voltage regulator and synchronizers.
Basic car model
Under base model car means any machine that will be taken as a basis in the manufacture of an electric vehicle.
Since the basis of any electric car is its lightness, which is directly proportional to the size, the material from which it is made, it is advisable to take small cars as a basis.
Agree, it will be difficult from Toyota Land Cruiser prado make an electric car.
Domestic VAZs, famous Cossacks, Slavuta, OKA are good for such purposes.
From foreign Fiat 126 and other small cars up to 2000 release.
You can make your own original body, but the complexity of the work and their high cost repulses many from this idea.
Electric motor
The electric motor is chosen depending on the size of the car and the option for connecting it to the car.
If you connect it to a gearbox, then the electric motor, even with a small power (5 - 7 K watts), will be able to move the car from its place.
When connected via a drive axle, a more powerful electric motor is needed. And the higher the overall weight of the car, the more power the future motor should be.
An electric motor with a minimum power installed on a small machine has a speed limit of 75-80 km / h (provided that the motor is directly connected to the gearbox).
By purchasing an electric motor with a higher power, you do not need to worry about additional energy consumption. These costs do not depend in any way on the mileage traveled and the power of the electric motor.
Battery
When choosing a battery, it is better to focus on energy carriers with lithium.
They can be used without recharging for 5 hours of continuous driving at a maximum speed of 80 km / h.
The total service life of such batteries is on average 5 years. Lithium energy is an expensive option.
As a less expensive alternative, you can choose lead-acid batteries... Such energy carriers have a shorter service life (on average 1-2 years) and are discharged after an hour of intensive traffic.
In order for the batteries not to wear out so quickly, it is necessary to select them correctly in the appropriate volume.
Energy carriers of small size fail earlier, as they wear out strongly, being completely discharged in the process of movement. Therefore, it is better to purchase one large battery with an increased resource.
Heating system
If the owner of an electric car expects to use it in the cold season, it is necessary to consider the heating system.
Heating a car using the electric power of the engine is very costly. In this case, the battery will not charge even for one trip.
Therefore, it is better to install a gasoline heater or a seat heating system. For all other electrical equipment in the cabin, it is better to purchase a separate energy carrier.
Power regulator
A very important part in an electric car is the power regulator, which is needed to adjust the traction of the electric motor.
The most reliable are American-made regulators. Due to limited finances, you can purchase its Chinese counterpart.
Regulators are selected depending on the power of the current. For everyday driving, a standard 150 volt regulator will do.
Also, in the electric car, in place of the removed generator, you need to mount a converter that performs similar functions.
Electric cars for children
Of course, you can make an electric car for your child, but is it worth the effort? After all, now they are already sold in full
So let's take a step-by-step look at the work done.
The guys from Lithuania took the old Vaz-2106, even demonstrated that it works - they installed the battery and started the engine internal combustion.
Most likely the guys used the prototype as an example -.
In principle, a pretty good choice of car, VAZ 2106 is enough light car... At the same time, the car is not the smallest in body size with large overhangs relative to the axle of the wheels in front and behind. There is quite a lot of space at Vaz-a engine compartment and in the trunk - this is where the craftsmen installed a whole battery of batteries.
Let's go back to the engine. As far as can be judged from the video, it was decided to use a 12 kW DC motor for the electric drive, most likely with a supply voltage of 110 volts. By appearance, it can be assumed that similar engines are used in electric cars or industrial devices.
12 kW in terms of approximately 17 hp - which most likely does not promise great dynamics assembled car... However, I would like to note that the internal combustion engine has been dismantled from the car, which in fact makes up 80 percent of the car's weight. By itself Vaz-a body not heavy.
I would like to note one not very positive moment - the guys decided to use their own mechanical box gear vase. It is not known whether they had to alter some of the design features of the gearbox (say, remove the synchronizers), but the video clearly shows that the gears are shifted without connecting and disengaging the clutch.
A very bad moment was noticeable when one of the authors touches the gearbox shaft with his foot and on different gears can't stop him. Then it turns on neutral gear and the shaft is spinning anyway. At the same time, a rather distinct noise is heard and the shaft continues to rotate, although it can be stopped with a little effort.
This all suggests that the box is not in better condition, most likely it will experience quite large losses. If we consider that the box itself will add the weight of the car, as well as its gear ratios in principle, they are not very relevant when using an electric motor (the torque at different speeds of the engine is almost the same) - it is possible to use a native box was not the best solution.
Although the box with the clutch block made the installation process much easier.
As far as we could understand from the video, the guys welded the clutch disc to the electric motor axis, and also welded a frame from the corner to mount the engine in the engine compartment.
From the same corner, a frame was assembled and welded with the help of which the clutch disc on the electric motor was connected to the clutch disc on the gearbox.
In the course of the entire video, it was not possible to understand whether the creators use this clutch for its intended purpose - most likely not.
After assembly, one of the authors demonstrates to us how the car drives into the garage by itself. Most likely, only a regular battery is used for recharge, and it is enough for the car to drive backwards into the garage by itself. You can even see sparks fly when the motor is directly connected to the battery.
Now, to control this mighty beast, it was necessary to assemble a strong power controller. The test was carried out from a voltage of 24 Volts (2 batteries of 12 Volts each). The only thing that can be seen in the video is that most likely some kind of microcontroller and several field-effect transistors were used (there are only 3 of them in the 24 Volt circuit). Most likely, the field workers do not get very hot, since the authors of the video boldly touch the radiators with their hands when the electric motor is running.
The final videos demonstrate the operation of the car, including on the track.
Here you can clearly see how the car looks after full cycle assembly. The authors installed 5 batteries in a rather large trunk. It is noticeable that a switch is immediately installed for emergency shutdown of all batteries from the trunk, perhaps a current fuse is installed nearby, or maybe it is an automatic relay that closes the contacts when the system starts. In general, there are any solutions that are, in fact, very important for the safe use of such powerful electrical systems, and at the same time they do not change the essence of the process functionally.
Right there in the trunk, we can notice the absence of a spare wheel - a very correct solution to lighten the car.
Three more batteries are installed in the engine compartment. As we discussed above, there is a lot of space in the engine compartment of the Vaz, if, in addition to everything, we take into account that the engine used in this design is quite small compared to the internal combustion engine.
It will be very correct to decide on the arrangement of the batteries in the front and rear parts evenly, this will have a very positive effect on the weight distribution of the car, and therefore on its stability on the road - handling.
The new 96-volt control unit now looks quite different. It is assembled in a beautiful shiny aluminum case, and then thoughts creep in that it may even be factory-made. Immediately next to the control unit hid a standard accumulator battery, for food on-board network auto. Now, to charge it, you also need a voltage converter and it probably lies in the same box of the control unit.
Power accumulators are much larger than the standard one. It can be assumed that most likely these are serviced traction batteries (plugs are visible on each section, battery cell).
We also managed to find the official website of the SIAP battery manufacturer http://www.siap.pl/firma.html - the company deals specifically with the production of traction batteries, unfortunately what type is not described (most likely they are lead-acid).
Total battery capacity 110 Ah
Operating voltage 96 Volts
At the same time, as we remember, the motor power is 12000 watts
That is, each battery at a voltage of 12 volts produces 100 amperes per load - roughly equivalent to 1200 watts. Quite permissible values, given that such currents will flow only when full load... Most likely, the batteries do not even heat up with uniform movement and work in a stable mode.
In the video where the car stops and starts again at a traffic light, you can see that the current reaches 178 Amperes (178 A * 96 Volts = 17080 Watt). This is even more than the rated power of the engine. By the way, I would like to note that many motors can operate in short-term overload conditions up to double the rated power.
As a result, according to the assurances of the authors, the VAZ 2106 electric car can
- charged from a 220 Volt network within 7-8 hours
- travels 50-60 km on a full charge
- maximum speed 70 km / h (on the video you can only watch a demonstration of movement at a speed of 40 km / h)
Will someone be able to repeat the experience of such talented masters. Or maybe such cars will finally be put into production?
DIY electric car in THREE DAYS! Video step-by-step instruction creating a homemade electric car!
A team of enthusiasts from Australia has set the task of rework ordinary car into an electric car. The task seems to be not difficult (when you know how), but the timing is amazing ...
The first day
It usually takes 6 to 12 months to convert a car to an electric vehicle. We set out to do it in a week. We wish there were more electric vehicles on the road, but that requires finding ways to reduce the time and cost of rework. In the future, it would be nice to see auto services for converting conventional cars into electric ones.
I worked on a project with my friend Michael from Gilong, Victoria. We decided to redesign his Daihatsu Charade (same model as mine) with an inexpensive rework package made in China.
For the last few months we have been preparing for the project by purchasing necessary spare parts, and manufacturing the missing components (such as the clutch and the adapter for connecting the electric motor to the gearbox). When setting up a permanent rework facility, such things can be automated. For example, the gearbox adapter has already been converted to CAD format, so the production of these parts using laser cutting can be set up. We have also prepared a detailed work plan and estimate, which will be published to help other enthusiasts.
I also invited many people interested in electric vehicles to participate in our redesign project. Many agreed to come and yesterday we had about 10 people, with whose help we did much more work than planned. Everyone was very organized and self-employed in the project, and the skills of some were simply amazing. We had mechanics, engineers, painters, video and photo operators, electricians, and my wife Rodemary cooked food for everyone!
On the first day, we removed the internal combustion engine and all related systems, such as exhaust and fuel, from the car. We also installed an electric motor and gearbox connected to each other. They also mounted the engine mount to the car body and began to manufacture a platform for installing batteries. By my calculations and with the help of such a wonderful team, we did the work for which 3 days were allotted.
The teamwork was excellent, many of those who helped us took a day off at work and received a lot of positive emotions. Teamwork to create an electric car is awesome!
Video - day one:
Second day
Saturday morning, just woke up after a very long Friday day. 6 more people slept with us under the same roof:
We finished installing a set of batteries in the back of the car and even connected them together. The rear of the car looks like a finished product, which is good news!
The more complex design of the battery frame in the front is almost complete (there will be more welding works inside the pallet alignment compartment). Today we will install the pallet, clean and paint.
The wiring for the instruments was made and a voltmeter was installed. Thanks Joel!
The engine and gearbox are installed, secured and checked. Michael, John and the team - great work!
Erick has installed a vacuum pump, all that remains is to plug it in.
Brackets for wiring cables under the bottom of the car are installed, it remains to finish the wiring.
Today we have to install a DC converter, a switch vacuum pump, battery charging, emergency brake and control unit. Then we will connect all this.
The progress of the second day was less noticeable as basically it was the "finishing touches" of the first day, wiring and installation of small equipment inside the car. Visually, this is not as impressive as dismantling the internal combustion engine and installing an electric motor with a box.
Be that as it may, these steps can take several months for single designers.
If we compare this project to the project of my first electric car, then in the first day as much was done as I did in the first 6 months! On the second day, we did the work of the next 5 months of my independent work... We are now at the stage of completing the wiring - I was at this stage 3 days before the test drive. Today I hope we will take this kid for a walk!
I originally planned to finish the project in a week and was a little nervous about how many people had come forward to help. I thought all this would distract me from the actual conversion work. Despite this, the opposite happened - thanks to all these people, we have done so much. I don't think it would be possible if only Mike and me were working. It can be concluded that the work on the manufacture of some parts takes a long time. For the next project, it will be necessary to develop a work plan to accelerate such work. For example, make a template for making battery trays.
Video - day two
Day three
After a long day at work, by 11 o'clock in the evening, we left for the first test drive in Michael's new electric car. Just 3 days after the start of work!
Yesterday I spent most of the day figuring out how to connect the tubes of the electric pump, and this required making several adapters. We also made the power cable routing under the bottom of the car. Andrew did an excellent job of connecting all 12 volts and 96 volts. The controller board that came along Chinese set perfectly fell into place and we quickly connected it.
In the morning we cleaned and painted the front battery tray and installed it after lunch. All metal work is excellent. And the painting is done very professionally, so everything looks just super!
Many people helped us that day. At some point, one group was doing the wiring under the car, another was pouring oil into the transmission, and the third was making the missing parts.
By the evening we were so close to completion that everyone added pace. Finally, all connections under the hood are completed and all the electrics are installed. First of all, we checked all 12 volt devices to make sure everything works with the “ignition” on, then we connected the 96 V power supply and checked the vacuum pump brake system and DC converter. After making small adjustments to the vacuum pump switch, the brakes worked as expected. Then we connected the converter to 12 V system, it worked perfectly.
We ended up connecting the last motor cable and starting the motor. Fortunately, he spun the wheels in the right direction on the stand. Despite the heavy rain, we could not resist the first trip. First, we made a few circles around the building - everything works fine, despite the increased weight, thanks to new suspension T-shirt. The engine runs very quietly and you can change gears very quickly without a clutch. Everyone was very happy with the first test drive.
There were still a couple of small problems, such as a small oil leak from the transmission, and the car's acceleration seemed weak (peak current was less than 100A), most likely due to some kind of connection error. On Sunday we have a rest and on Monday I think we will solve these problems. There will also be cleaning and cosmetic work before going through the official inspection of the car.
As a result, we got a great project that was completed much faster than planned.
