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Optimization of a 1974 VW Optimization of a 1974 VW Electric BugElectric Bug
Michael BoyleMichael BoyleMichael LaBeachMichael LaBeachAndrew MagalettiAndrew Magaletti
Rabei RabeiRabei Rabei
ProjectProject
ProblemsProblemsHillsHillsSpeedSpeedRangeRangeLightsLights InteriorInterior
Project SpecificationsProject Specifications
Increase TorqueIncrease Torque Increase SpeedIncrease Speed Increase RangeIncrease RangeDistribute WeightDistribute Weight
Design ConceptDesign Concept
Battery CageBattery Cage 24V Field Charge24V Field Charge Battery ConfigurationBattery Configuration Rejuvenated BatteriesRejuvenated Batteries Heat Sinks on Heat Sinks on
ControllerController Air Induction for MotorAir Induction for Motor Hydrogen VentilationHydrogen Ventilation
Battery CageBattery Cage DesignDesign
Material Material CostCost Efficiency Efficiency
Battery Cage AnalysisBattery Cage Analysis
Battery Cage Stress AnalysisBattery Cage Stress Analysis
Stress AnalysisStress Analysis Displacement AnalysisDisplacement Analysis
Battery ConfigurationBattery Configuration
Addition of 6 Addition of 6 batteriesbatteries Increases rangeIncreases rangeSeries/ParallelSeries/Parallel
Field Voltage PackField Voltage Pack Increases speedIncreases speed Increases torqueIncreases torque
Range - CalculationsRange - Calculations
Range Calculations
RangeEnergybattery
Energyused
mile
I1 260A hr 20 Ah capacity x 2 for parallel configuration
Cf .57 Conversion factor from Trojan website
Vpack 72V
Ebatt Vpack Cf I1 Eused 200W hr
mi
RangeEbatt
Eused Range 53.352mile
Speed - CalculationsSpeed - CalculationsActual Top Speed
Factoring rolling friction give us a better estimate of the top speed.
P1
2 air Vc
3 Af Cd Vc Fr
Fr r Wcar Fr 125.92N
Vc 60mph 61mph 75mph
Ptest Vc 1
2 air Vc
3 Af Cd Vc Fr
Ptest 70.14mph( ) 15kW
Varying the V value in the above equation, a top speed of70.14 mph can be reached with a 15kW motor.
Power vs. Velocity
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
20.00
55 60 65 70 75 80
Velocity (mph)
Po
wer
(kW
)
Battery RejuvenationBattery Rejuvenation
Rob MatthiesRob Matthies ProcessProcess
Analyze BatteryAnalyze Battery Recondition BatteryRecondition Battery
Rejuvenation ProcessRejuvenation Process
Analyze BatteryAnalyze BatteryDetermine discharge rateDetermine discharge rateNatural voltageNatural voltage
Rejuvenation ProcessRejuvenation Process
Recondition BatteryRecondition BatteryUse a battery reconditionerUse a battery reconditionerShake batteryShake batteryCharge, Discharge and RepeatCharge, Discharge and RepeatGood BatteryGood Battery
Heat SinkHeat Sink
Regulating Regulating Controller Controller TemperatureTemperature
Motor Air InductionMotor Air Induction
Keep motor cool Keep motor cool at 96Vat 96V
Size of fanSize of fan
Hydrogen VentilationHydrogen Ventilation
Fan Size Fan Size Fan MountingFan Mounting
Cost AnalysisCost Analysis
Conversion ManualConversion Manual
ConclusionConclusion
Specifications metSpecifications metUnder BudgetUnder Budget
Future PlansFuture Plans
Battery revivalBattery revival Shaker TableShaker Table
Order PartsOrder Parts Heat Transfer AnalysisHeat Transfer Analysis Finalize Cage DesignFinalize Cage Design
ReferencesReferences Brant, Bob. Build Your Own Electric Vehicle. TBA Books, Blue
Ridge Summit, PA. 1994 “Evalbum”, (11/6/08), www.evalbum.com Barkley, Michael.(9/10/08) “Mitsubishi Eclipse Conversion”,
(TexomaEV.com) http://www.texomaev.com/ (Accessed: 9/26/08)
AcknowledgementsAcknowledgements
Rob MatthiesRob MatthiesDr. HollisDr. HollisAndrew ParkAndrew ParkMichael BarkleyMichael BarkleyDr. ClarkDr. Clark