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Presented at Penguicon 7.0 in 2009. This is a presentation about what you might need to get started building your own Electric Vehicle (EV) and where you can start learning more. Basically, go buy a used one as you will spend about the same amount.
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Hack Your World -> Who Needs an EV1
When you can build your own!
Rich Elswick - [email protected]
Doug Houseman
Goals
• Introduce EV tech• Present sources for each of these parts.• Show the costs associated with parts• Allow you to determine if you want to pursue
EVs as a mode of transportation.• If so, provide more information to continue
your quest.
Most of the fundamental ideas of science are essentially simple, and may, as a rule, be expressed in a language comprehensible to everyone. - Albert Einstein
http://www.flickr.com/photos/tjc/
Who Needs and EV1Discussion Topics
• Why EVs• Build verse Buy • Components of an EV (20-30
minutes)o Batterieso Battery Controller o Motoro Motor Controllero Charging System o Auxiliary Systems
• Cost BOM• Buy verse Build • Sources • Discussion of the Future (20-30
minutes)
GEARHEADS!
Why EVs?
• Fuel costs up to 50% lower • Lower maintenance costs • Increased rider comfort • Higher initial torque provides acceleration • Exemption from emission inspections • Convenience of home refueling • Evs are “green” vehicles. • Cost of Building ~$10,000 or lower - $75,000. • The Future is Here!
Any intelligent fool can make things bigger, more complex, and more violent. It takes a touch of genius -- and a lot of courage -- to move in the opposite direction. - Albert Einstein
Why EVs?
If it is too much, then...
make a Segway - $5000 down to $1500...
http://www.flickr.com/photos/hackaday/
http://www.tlb.org/scooter.html
Why EVs?
2005 Average distance of commutes < 20 miles.
Gasoline Vehicle ------> Electric VehicleComplex (lots of parts) ------> Simple (few parts)
Images from: http://www.slideshare.net/guest36c13b/review-of-electric-vehicles
Build vs. Buy
• When you can't buy it, build it yourself!• Cheaper• You understand your vehicle• It is mostly New and Working properly\• The fun of it
SAFETY! SAFETY! SAFETY!
http://www.flickr.com/photos/locutis/
Components of an EVBatteries
• Considerations• Types
o Lead Acido Nickel Metal Hydride - NiMH- 156 shown
o Lithium Ion
o Others such as
Lithium Phosphate Nickel Cadmium
Components of an EVBattery Controller
Purpose in Life is to Monitor the State of the Battery Connect/Disconnect Batteries from Vehicle Characteristics are: • Current Sate of Charge level ( or Depth of Discharge) • State of Health of batteries• Temperature monitoring• Voltage levels• Precharge• Typically an embedded microcontroller system.• Balancing a Pack - I don't recommend. • Charging of Pack Management- sometimes called Charge
Management System
Components of an EVBattery Controller
Suppliers - list at end. • Lead Acid generally doesn't need it. Period checks with a
Multimeter. • Advanced Technology - there are generally no contollers
for these, but they need them!o Prevent over discharging of moduleso Prevent over Charging of modules
If you don't have this then.... • Controller from Hybrid at Junk Yard!
http://www.flickr.com/photos/msciba/
Components of an EVMotors
DC • Simple - Uses same voltage levels as Batteries• May require DC-DC converter• Brushed vs. Brushless
AC
• Requires an DC-AC Inverter • Requires a controller matched to the motor
Components of an EVMotor Controller
• This is what controllers the amount of Current delivered to a motor, thereby driving the wheels at the speed you want.
• You need to match the expected voltages to the battery pack and motor.
• Protect gears of transmission.• Lots of choices, large cost.• Capacitor bank - precharge be careful.• Open source DC Motor controller design discussed at:
http://ecomodder.com/forum/showthread.php/paul-sabrinas-cheap-144v-motor-controller-6404.html
Components of an EVCharging Systems
• Onboard vs. Offboard vs. both.
• Long term usefulness beyond first car.
• Critical Component / time period
• Communications between pack / batteries
Russco Charger
Components of an EVAuxiliary Systems
• Air-Conditioning Options• Brake Upgrade Options• Power Steering Options • Automatic Transmissions in EVs
o Most conversions use Manual transmission
o Clutch vs. Clutchless• Cold Weather
o Heating Batterieso Heating the car - Kerosene
• Rusty parts on older car.• Heavier Springs
• Oh, I forgot - The CAR!
Cost BOM
Stay tuned for more in the future.
Look for a BOM list / app to showcase how much it may cost for the parts at www.RichElswick.com
Buy vs. Build
• Buy it, BUY IT NOW!!!!!!!! Do not pass Go! • Cost estimates to build and operate an EV state the
cost to be 3* that of gas.• BUT, I have also seen that over a 5 year period, the
cost difference of operating a Gas car is $14,000 more than an EV.
• Your going to spend about the same amount to build
one as you can for buying a used 'built' EV. • I have between $3000-6000, some as low as $1000.
BUT... depends on range/speed.• Lawn mower, motorcycle, 3 or 4 wheeler
http://www.flickr.com/photos/9229859@N02/
Goals
These were my goals for this presentation • Introduce EV tech• Present sources for each of these parts.• Show the costs associated with parts• Allow you to determine if you want to pursue
EVs as a mode of transportation.• If so, provide more information to continue
your quest.
http://www.flickr.com/photos/a_t_ljungberg/http://www.flickr.com/photos/ekilby/
Suppliers • Motor
o Advanced DCo Brusao Eteko D&Do Lyncho Netgaino Perm-Motoro Sevcono Siemenso Scott
• Controller o Alltraxo CC Powero Curtiso Kellyo Navitaso Sevcono Zapio Zilla
• Batteries o A123 Systemso Exideo FireFlyo MKo Odysseyo Optimao Thunderskyo Trojano US Battery
• DC-DC converter o CC Powero Iotao Sevcon
• Vacuum Brake Pump o Ready Brakeo Thomas
• Battery Charger o Zivano Manzanita Microo Russcoo Lester
LOTS more than this, but this is a good start.
Of course, contact your local Junk Yards!
http://www.flickr.com/photos/lifeontheedge/
SourcesSlide References:• Best Guide to DIY Electric Vehicles • Battery Electric Vehicle - Wikipedia entry • Extensive Breakdown of EVs and HEVs verse Gasoline• Basic Powerpoint slides based about EVs• EV Album - list of recent mods w/ stats• Michigan Electric Auto Association - a Chapter of the Electric Auto Association • EV Canada - Great resource about EVs in general - Best FAQ list I have seen yet.• Electric Car Society - established 1982. • Hybrid Cars - good source of current prices and new cars• Endless Sphere Forums - good discussions related to EVs. • Eco-Moder - Decent forum discussions• AutoBlogGreen.com• National Electric Drag Racing Association • Electo7 - a Co-Worker's EV conversion w/ a kit car. • EV Discussion List• EV Forum.net
• Open Source Car Projects - not so open source
o The Open Source (OS) Car Project o Society for Sustainable Mobility
http://www.flickr.com/photos/colinedwards/
Discussions• Questions
• Tesla, Fisker, Tata, Chinese OEMs.• Battery issues?• Fuel Cells?• EV Auto Shops and less need for OEMs.• Future EVs - why the Big OEMs will
dominate Rich Elswick - [email protected] Houseman
http://www.flickr.com/photos/laenulfean/
Discussions• The following were discussed about
additions to this slide at Penguicon 7.0 in 2009:
• Regulations - make sure you know them for
your state if you do build a conversion.
