Difference between revisions of "TF Project JeV 1989"

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:1987-1995 Jeep Wrangler YJ
+
=Budget=
=Background=
+
{| border="1"  |cellpadding="20" cellspacing="0
 +
|Cost ||Item
 +
|-
 +
|7,000 ||  http://hpevs.com/catalog-ac-75-27.26.htm 96 Volt AC75  motor + controller kit
 +
|-
 +
|4,000 ||http://www.canev.com/batteries.php  Lithium batteries  > 30 3.2 volt 300 Ah
 +
|-
 +
|3,000 ||Battery Management
 +
|-
 +
| 850 || [http://www.ev-propulsion.com/adapterscouplers.html adapter plate ]
 +
|}
  
The Jeep Wrangler YJ was introduced in 1987. In 1988 some minor changes were made including the way the upper half doors attached to the lower half doors. Little changed for Wrangler YJ jeep parts in model years 1989 and 1990. Starting in 1991, the 4.2 liter in-line 6 cylinder engine was upgraded to the fuel injected 4.0 Liter High Output engine which remained in Jeep Wranglers for the next 15 years. In 1992, the classic roll bar was changed to the more elaborate cage which provided the Jeep Wrangler YJ rear passengers with greater protection. With the exception of minor interior and trim details, Wrangler YJ Jeep parts remained unchanged in model years 1993, 1994 and its final production year 1995.
+
= Design=
 +
==ac50==
 +
Probably use two AC 50 motors in series with separate packs
  
=Components=
+
Midvale Utah distributor $7454
  
 +
http://www.electriccarpartscompany.com/650-Amp-HPEVS-AC-50-Complete-AC-Vehicle-Kit_p_143.html
  
==Marker lens==
+
{| border="1"  |cellpadding="20" cellspacing="0
 +
|Cost ||Item
 +
|-
 +
|4300 ||AC 50 motor, controller, & harness from http://www.electricmotorsport.com/store/ems_ev_parts_motors_ac50.php
 +
|-
 +
|6300|| 96 volt, 100 Ah lithium battery pack http://www.electricmotorsport.com/store/ems_ev_parts_batteries_lpf_gbs_kit96.php
 +
|}
  
http://www.jeep4x4center.com/product-information.asp?number=56001424
 
  
 +
http://hpevs.com/
  
==Hard Tops==
+
Motor- transmission adapters
  
http://www.jeep4x4center.com/jeep-hard-tops/cj7.htm
+
See http://www.canev.com/KitsComp/Components/Adapter%20page.htm
  
==Soft Tops==
 
  
http://www.jcwhitney.com/cab-top-and-tonneau-combination/p2002742.jcwx?filterid=c16047d1202y1989j4&_requestid=698242#
+
===Battery Management system (BMS)===
  
==Carpet==
 
  
http://www.jeep4x4center.com/jeep-carpets/index.htm?gclid=CLvN6IjB9agCFQo0QgodzwncSQ
+
 
 +
Orion and Elithion are two polular controller manufacturers
 +
 
 +
 
 +
http://elithion.com/comparison.php
 +
 
 +
==ac75 ac150==
 +
 
 +
http://hpevs.com/catalog-ac-75.htm
 +
 
 +
 
 +
http://www.acpropulsion.com/
 +
 
 +
 
 +
Liquid cooled lcm150
 +
 
 +
http://www.acpropulsion.com/datasheet/LCM-150.pdf
 +
 
 +
 
 +
Forum for AC75
 +
 
 +
http://www.diyelectriccar.com/forums/showthread.php/hpevs-ac-75-data-79186.html
 +
 
 +
= References=
 +
 
 +
EV discussion list
 +
 
 +
http://www.evdl.org/index.html
 +
 
 +
http://avt.inel.gov/index.shtml
 +
 
 +
== Builds by others==
 +
 
 +
Kris motors
 +
 
 +
http://krissmotors.blogspot.com/
 +
 
 +
Eric Tischer's AC conversion
 +
 
 +
http://etischer.com/awdev/
 +
 
 +
http://www.electric-cars-are-for-girls.com/ac-conversion.html
 +
 
 +
http://www.evalbum.com/3399
 +
 
 +
http://www.evalbum.com/1095
 +
 
 +
http://www.evalbum.com/2101
 +
 
 +
CRx (1989-1991)
 +
Honda CRX/del sol
 +
 
 +
http://www.evalbum.com/1250
 +
 
 +
http://www.evalbum.com/1648
 +
 
 +
http://www.evalbum.com/3505
 +
 
 +
http://www.evalbum.com/2778
 +
 
 +
http://www.evalbum.com/2222
 +
 
 +
 
 +
VWs
 +
 
 +
http://www.evalbum.com/684
 +
 
 +
http://www.evalbum.com/3254
 +
 
 +
http://www.evalbum.com/556
 +
 
 +
http://www.evalbum.com/2728
 +
 
 +
GEO tracker
 +
 
 +
    * Ground clearance: 7.9 in.
 +
    * Curb weight: 2238 lbs.
 +
    * Wheel base: 86.6 in.
 +
 
 +
http://eastidaho.craigslist.org/cto/2378173601.html
 +
 
 +
Toyota MR2 (1985-1989)
 +
 
 +
 
 +
http://www.amphibike.org/index.cgi?page=pages/3_wheels/mr2
 +
 
 +
=Electric Power plants=
 +
 
 +
Below are the motors and generators you want for the EV
 +
 
 +
http://www.industry.usa.siemens.com/drives/us/en/electric-drives/hybrid-drives/Documents/elfa-components-data-sheets.pdf
 +
 
 +
==Electric conversion kit==
 +
===ReVCon===
 +
http://www.revconversions.com/electric_vehicle_conversion_products-jeep.htm
 +
 
 +
 
 +
REVConversions is the only conversion company that has been able to successfully convert 4-wheel drive all-electric Jeep Wranglers that function and shift properly in every gear in both high & low range driving modes.
 +
 
 +
The first Wrangler conversion that was made for the Jeep Tour Industry retains the automatic transmission. The 160-volt drive system (twenty 8-volt batteries) drives a Warp-11 DC motor with our own proprietary forced-air cooling system.
 +
 
 +
The first Wrangler conversion kits are available for immediate delivery.
 +
 
 +
For Pricing and to Order: Contact Us
 +
 +
 
 +
Verde Sustainable Energy, Inc.
 +
Ian Wickson (President)
 +
Bruce Berkson (General Manager)
 +
Phil Brown (Production Manager)
 +
250 Cherry St., Suite B
 +
Cottonwood, AZ 86326
 +
 +
 
 +
Office: (928) 282-0101
 +
    Cell: (928) 254-0196
 +
    Fax: (928) 649-0102
 +
Email Us: phil@revconversions.com
 +
 
 +
 
 +
=== CANEV===
 +
 
 +
http://www.canev.com/KitsComp/Universal%20Kit/universal%20kit.htm
 +
 
 +
==Motors & Controllers==
 +
 
 +
{| border="1"  |cellpadding="20" cellspacing="0
 +
|Spec ||[http://www.metricmind.com/products/siemens-1pv5135-ws18 siemens-1pv5135-ws18] [[http://www.hec-drives.com/Specs%20Siemens%201PV51XX.pdf]]||[http://www.metricmind.com/products/mes-200-330 mes-200-330] ||[http://www.evparts.com/products/street-vehicle/motors--dot/48-to-96-volt-street-vehicle-motors/mt5615.htm AC-50] [http://www.grassrootsev.com/motorsac.htmk][http://www.electricmotorsport.com/store/ems_ev_parts_motors_ac50.php] || [http://topekaelectricmotor.com/files/Baldor-Motor-and-Curtis-123.jpg  Baldor  TE MR-50] ||[http://en.wikipedia.org/wiki/AMC_Straight-4_engine 2.5 L 4 cyl AMC 150] [http://www.allpar.com/mopar/amc-25.html mopar]
 +
|-
 +
|Inverter DC voltage (Volts) ||520-900 ||185-400 || 130 max || 72-96 ||
 +
|-
 +
| Rated RPM || 3500 || 2850 || 3500 ||
 +
|-
 +
| Max RPM || 10,000 || 9,000 || 6500 || 5000 ||
 +
|-
 +
|Rated Continuous Power (kW) || 61 || 40 (400 V 100 A or 200 V 200 A) ||  20 (130 VDC 650 A; 15 Hp) ||
 +
|-
 +
|Peak Power (kW)|| 150 || 87@5000 RPM || 49 (67 Hp) @ 3000 rpm|| (50 hp) || 60 kW (80 bhp x 0.75) @ 3000 rpm
 +
|-
 +
|Rated Torque (Nm)@phase current (A) || 160@145 ||130 ||  (150 ft lbs) || (150 ft lbs)
 +
|-
 +
|Peak Torque (Nm)@phase current (A) || 370 @ 300 || 300 || 110 ft-lb || ||  183@ 3500 RPM
 +
|-
 +
|Max Current (A) || 400 peak / 282 RMS || || || 362 ||
 +
|-
 +
|Weight (kg)|| 90 || 80 || 115 lbs || 490 lb ||
 +
|-
 +
|Diameter (cm)|| 24.5|| 23.5 ||
 +
|-
 +
|Length (cm)|| 42.5 || 47.5 ||  ||
 +
|-
 +
|Cost (USD)|| 9161 || 7138 || 4620 (4390) || 4700 + 7700 ||
 +
|-
 +
|AC power inverter|| ? || MES TIM-600 ($5995) || Curtis Regen  model 1238-7601 || Curtes Regen 1238R-7601
 +
|-
 +
|HP/Torque curve|| [[File:SimensAC_TP.gif | 100 px]] ||  [[File:mes_200-250_TP.jpg | 100 px]] ||  [[File:AC50_MotorSpecs.png | 100 px]]  [http://www.evparts.com/cms/picts/products/MT5615%20Torque.PDF Torque curve]||  ||[[File:89_2.5LAMC150.png| 100 px]]
 +
|}
 +
 
 +
http://www.azuredynamics.com/products/force-drive/documents/AC90_DMOC645ProductSheet.pdf
 +
 
 +
http://www.azuredynamics.com/products/force-drive/documents/AC55_DMOC445ProductSheet.pdf
 +
 
 +
The AC motors have controllers which convert a DC source to an AC voltage with variable frequency to drive the motor speed.  Motors work best at higher DC voltages.
 +
 
 +
 
 +
[[File:EV_AC_motor_Performance_Comparison.png | 200 px]]
 +
 
 +
 
 +
[[File:EV_AC_motor_Performance_Comparison.xmgrace.txt]]
 +
 
 +
 
 +
Open source AC motor controller blog
 +
 
 +
 
 +
http://ecomodder.com/forum/showthread.php/paul-sabrinas-cheap-3-phase-inverter-ac-controller-10839.html
 +
 
 +
===Luminati configuration===
 +
The engine compartment includes:
 +
+99 Thundersky 4.25 volt lithium iron phosphate batteries (TS 100AH) = approx. 32 Kwh
 +
+200 horsepower MES DEA electric motor: MES 200-330 induction (compare to Chevy Volt’s 149 HP motor)
 +
+ Manzanita Micro PFC-40 (220v, 40 amp off board charger will charge the car overnight) charger
 +
+ MES-DEA – TIM600 (100kW) inverter
 +
 
 +
===DC power supply===
 +
440 AC input with 60 kW output (0-600 Volt , 0-100 A)
 +
 
 +
A 1500 lb box with dimensions 44 x 27 x 33 " ( 4 ' x 2' x 3')
 +
 
 +
http://www.us.tdk-lambda.com/hp/product_html/emhpower.htm
 +
 
 +
===Metric Mind motors===
 +
 
 +
 
 +
http://www.metricmind.com/category/ev-ac-drive-systems/ev-motors/
 +
 
 +
http://www.metricmind.com/products/mes-200-330/
 +
 
 +
http://www.metricmind.com/products/siemens-1pv5135-ws18/
 +
 
 +
=== 90 HP Siemens AC motor for Ford Ranger===
 +
http://www.commoditiesrecoverycorp.com/electricmotors.htm
 +
 
 +
http://www.zuglet.com/ev/fordsiemens/fordsiemens.html
 +
 
 +
===Electric Motor Sport ===
 +
 
 +
http://www.electricmotorsport.com/store/ems_ev_parts_motors_ac-induction.php
 +
 
 +
=== Kosov AC motors===
 +
 
 +
http://kostov-motors.com/tractionmotors/kostovevmotors%28ac-dc%29/
 +
 
 +
=== AC propulsion ===
 +
http://www.acpropulsion.com/products-drivesystem.html
 +
 
 +
===Warp -11===
 +
 
 +
The 160-volt drive system (twenty 8-volt batteries) drives a Warp-11 DC motor.
 +
 
 +
20 batteries => Try the US battery 8VGC-XC  (Length : 10-1/4” (260mm) Width : 7-1/8” (181mm) Height : 11-1/4” (286mm) )$150 each => $3000; change after 650 cycles;
 +
assuming about 80 miles/charge => 650 * 80 < 52,000 miles => 17 miles/$
 +
 
 +
If 30 mpg * 1g/$4 = 7.5 miles/$
 +
 
 +
Cost of electricity to charge batteries at $0.1 per kWh (in idaho its 7 cents)
 +
 
 +
 
 +
kWh = 10^3 Watt * hrs = 3.6 \times 10^6 Joules = 3.6 \times 10^6 Coul * Volts
 +
 
 +
 
 +
130 Amp*hrs = 469,000 Coul
 +
160 Volt * 469,000 Coul = 7.5 \times 10^7 Coul * Volt = 1 cycle of charge
 +
 
 +
cost per charge = $0.1 * 3.6 \times 10^6 / 7.5 \times 10^7 = $0.005 ??? too cheap must be mistake somewhere
 +
 
 +
 
 +
$2,673.75
 +
http://www.revoltevc.com/motors/warp11.html
 +
 
 +
 
 +
TransWarp-11
 +
$3,105.00
 +
http://www.revoltevc.com/motors/transwarp-10.html
 +
 
 +
(72 Volts*453 Amps= 33 kWatts =43.7 HP of power ; using 18, 8 Volt batteries =>  227 Amps)
 +
 
 +
$2,175.00 controller
 +
http://www.revoltevc.com/controllers/netgain-controlls-warp-drive-dc-controller.html
 +
 
 +
$145.00 gas pedal
 +
http://www.revoltevc.com/controllers/netgain-controls-hepa.html
 +
 
 +
$300.00 liquid coolant system
 +
http://www.revoltevc.com/controllers/netgain-controls-liquid-cooling-kit.html
 +
 
 +
===DC-9===
 +
 
 +
The advance DC-9 that was used in this application is about $1550. The only alternative to that motor is the Netgain WarP-9 which is $1675.00. The Curtice controller is about $1500. There are others but not really sure about prices and specs. There are very few that can handle the high voltage and current that an EV conversion has. There is one controller that is the Rolls Royce of controllers Called the Zilla2000 with Hairball interface. These monsters can handle far more current and voltage than the Curtice can, it can also be programed to function on a given curve and limit the maximum current that it will allow through it. This controller is around $6000 with the interface. There really isn't a cheap way to do it so the thing will be drivable and reliable.
 +
 
 +
===Zilla===
 +
 
 +
Zilla motor controllers. He has an electric 914 that has 800ftlbs of torque at zero RPM
 +
 
 +
===Soliton1===
 +
 
 +
http://www.evolveelectrics.com/Soliton1.html
 +
 
 +
==Batteries==
 +
 
 +
===Zinc-air===
 +
 
 +
http://www.electric-fuel.com/evtech/index.html
 +
 
 +
 
 +
===Nano phosphate ext===
 +
 
 +
http://www.a123systems.com/products-systems-energy-core-pack.htm
 +
 
 +
http://www.a123systems.com/lithium-ion-battery-technology.htm
 +
 
 +
http://www.sfgate.com/cgi-bin/article.cgi?f=/g/a/2012/06/12/bloomberg_articlesM5BRQP0UQVI901-M5IU0.DTL
 +
 
 +
=== Lithium===
 +
 
 +
 
 +
http://www.valence.com/
 +
 
 +
 
 +
A123 system battery packs(currently not selling packs To consumers)
 +
 
 +
http://www.a123systems.com/products-systems-energy-core-pack.htm
 +
 
 +
 
 +
lithium iron phosphate
 +
 
 +
Recharging in minutes not hours?
 +
 
 +
http://www.tgdaily.com/general-science/41686-mits-revamped-li-ion-batteries-fully-recharge-in-seconds-not-hours
 +
 
 +
http://ceder.mit.edu/
 +
 
 +
 
 +
http://electriccarinternational.com/
 +
 
 +
http://kostov-motors.com/tractionmotors/kostovevmotors%28ac-dc%29/lithiumbatteriesbmsandchargers/
 +
 
 +
http://lithiumpros.com/products/
 +
 
 +
http://www.valence.com/energy-storage/xp-12v-19v-lithium-phosphate-battery-module
 +
 
 +
Thunder sky (now called Winston Battery) 4.2 Volt
 +
 
 +
http://thebackshed.com/basiclynatural/ViewItem.asp?CL1=17&CL2=53&id=49
 +
 
 +
http://ev-power.com.au/webstore/
 +
 
 +
http://ev-power.com.au/webstore/index.php/12v-4-cell-100ah-lfp-battery-module.html
 +
 
 +
 
 +
http://elitepowersolutions.com/packages.html
 +
 
 +
=== Lead===
 +
Typically it takes 15-20 lbs of lead to achieve 1 mile in range. A Rule of Thumb is that 1/3 of the EVs weight should be batteries; the other 2/3 represents dead weight (i.e. frame, suspension, body, motor, etc).
 +
 
 +
If you want to have 1/3 to 1/2 of the finished weight in fuel; then the initial curb weight of the vehicle should be less than 3000 lbs.  The 1991 Jeep Wrangler Renegade (YJ) has a gross vehicle weight of 3090 lbs to 4700 lbs.
 +
 
 +
http://www.acterra.org/ev/files/batteries_1.html
 +
 
 +
 
 +
Try the US battery 8VGC-XC  $155
 +
 
 +
==Generator driven EV==
 +
 
 +
http://www.polardcmarine.com/polarpower/wp-content/uploads/2010/07/26Kw_Brochure_LowerRES.pdf
 +
 
 +
 
 +
See solution #2
 +
 
 +
http://www.evconsultinginc.com/articles/hybridizing_dc_system.html
 +
 
 +
 
 +
http://www.diyelectriccar.com/forums/showthread.php/generator-direct-power-ev-distance-48794.html
 +
 
 +
http://www.evconsultinginc.com/articles/hybridizing_dc_system.html
 +
 
 +
http://www.bladonjets.com/
 +
 
 +
==EV racing==
 +
 
 +
http://www.plasmaboyracing.com/
 +
 
 +
http://www.killacycle.com/
 +
 
 +
 
 +
http://www.thecoreiv.com/products/25.html?Itemid=15
 +
 
 +
=Portable generators=
 +
 
 +
;The generator should be rated to at least 40 kW
 +
 
 +
http://catalog.ameritempltd.com/viewitems/temporary-power/industrial-standby-generators?
 +
 
 +
==PTO units==
 +
http://www.electricgeneratorsdirect.com/power/40-59-kw-540-rpm-pto-generators.html
 +
 
 +
 
 +
http://www.voltmasteramerica.com/products/tractor1800.htm
 +
 
 +
http://www.hardydiesel.com/pto-generators/dl/Winco_PTO_Generator_Specs_W11PTOS.pdf
 +
 
 +
===Diesel engines for PTO===
 +
 
 +
YANMAR DIESEL ENGINE 90hp
 +
 
 +
http://www.dbsupplyco.com/
 +
 
 +
== Diesel Generators==
 +
 
 +
 
 +
[http://www.tadiesels.com/used/igen/igen-1062.htm Perkins 4.236 Diesel Powered Generator $6750]
 +
 
 +
http://www.perkins.com/
 +
 
 +
Diesel Electric
 +
 
 +
Phone: [801] 972 1836
 +
 
 +
Address: 652 West 1700 S,Salt Lake City 84104 Utah
 +
 
 +
Model: ElectroPak: complete unit with radiator ...
 +
 
 +
Power Zone Equipment (Center, Colorado near Alamosa)
 +
 
 +
http://www.powerzoneequipment.com/
 +
 
 +
[http://www.tadiesels.com/used.html#IGEN Industrial Generators from Trans Atlantic Diesels, Inc]
 +
 
 +
 
 +
http://www.dieselserviceandsupply.com/Used-Generators
 +
 
 +
== Gasoline Generators==
 +
 
 +
$3k
 +
 
 +
http://www.northerntool.com/shop/tools/product_200379773_200379773
 +
 
 +
Maybe 2 17 kW generators
 +
 
 +
http://www.electricgeneratorsdirect.com/power/10000-plus-watt-portable-generators.html
 +
 
 +
==trifuel==
 +
http://www.trexgenerators.com/Winco-HPS12000HE-10800-Watts-TriFuel-Honda-Engine-p-1053.html
 +
 
 +
== Example ==
 +
 
 +
http://www.electric-cars-are-for-girls.com/portable-generator.html
  
 
=Accessories=
 
=Accessories=
  
 +
==charging connector==
 +
 +
http://en.wikipedia.org/wiki/SAE_J1772
 
==Hitch==
 
==Hitch==
 
http://www.etrailer.com/hitch-1989_Jeep_YJ.htm
 
http://www.etrailer.com/hitch-1989_Jeep_YJ.htm
  
 +
rear bumper with hitch
 +
 +
http://cgi.ebay.com/ebaymotors/JEEP-WRANGLER-YJ-TJ-REAR-BUMER-HITCH-RECEIVER-_W0QQcmdZViewItemQQhashZitem3f0a0f8ed5QQitemZ270751731413QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories
 +
 +
 +
=trailers=
 +
 +
http://www.fthr.com/flatbed-commercial-utility-trailers/
 +
 +
=Removing vaccum from transfer case=
 +
 +
== Wrangler Forum==
 +
 +
http://www.wranglerforum.com/f8/vacuum-shift-motor-inexpensive-fix-87568.html
 +
 +
 +
==From Wrangler Forum==
 +
 +
http://www.wranglerforum.com/f8/by-passing-frt-diff-4wd-vacuum-78334.html
 +
 +
 +
 +
 +
1. jack up right frt. tire and place on jack stand
 +
(easier if not done on a day that snow is not packed on your jeep...lol)
 +
 +
2. unplug vacuum lines from the shift motor actuator and cap off you will not need them any more .
 +
 +
3.remove the four bolts holding shift motor on and remove it
 +
(don't forget to have a pan or towel on the floor to catch the very
 +
amount of lube that will come out)
 +
 +
4.now look at the axle see how the collar slides over to connect the two axle's together? you might have to turn the right tire a little as you use your finger to slide it to left all the way as the splines line up
 +
now your frt. diff is locked into fwd. ( that's a good thing for a jeep)
 +
 +
5.now take apart the shift motor.take a marker and put a dot on one side of the fork and a dot on the matching side of the housing so you will remember what way the fork faces( trust me it saves time..lol) remove the two e-clips holding the
 +
shift fork shaft in place and pull shaft out. discard everything but the shaft,fork and big e-clip
 +
 +
6.now put the shaft with the fork back in the housing (no e-clip yet)
 +
and move the fork all the way to the right that is where it is when the 4wd is locked in ( remember the collar you slide to the left to lock the axle's together?)
 +
 +
7. now get a spring or fuel line (like i did) and cut it to take up the space on the shaft so that the fork can not move to the right ( and yes the spring or hose needs to fit over the shaft and I am sorry i did not measure the length or i.d for ya but heck you need to do a little of the work yourself) tip: if you use a piece of hose it needs to be fuel and oil resistant ( mine has been set this way for two years)
 +
 +
8.after you get the spacer cut right put in the e-clip so the shaft won't come out.
 +
 +
9. reinstall on the diff. using a little gasket sealer or a new gasket and your almost done. top off the lube if you feel like the little bit that came out is a bad thing.
 +
 +
10. you are now done and have a much improved 4wd set up.
 +
you will not notice a drop in mpg, no change in handling ( transfer case disconnects the frt. drive). what you will feel is a good feeling knowing your frt. axle really is locked in when it's needed ( yep even when it is -7 degree's like it is here to day)
  
 
=Vendors=
 
=Vendors=
==http://www.jeepoemparts.com/==
 
==http://www.thepartsbin.com/catalog/parts.php?year=4294963356&make_text=1557&model_text=10852==
 
==http://www.jeep4x4center.com/yj/menu.htm==
 
==http://www.etrailer.com/vtk-1989_Jeep_YJ.htm==
 
==http://www.autotrucktoys.com/jeep/==
 
==http://www.jcwhitney.com/jeep-parts-jeep-accessories/j4s2.jcwx?TID=8995449&JCW=1&JCW_SRC=PPC&gclid=COiMrcnC9agCFRRigwod9EfVRw==
 
==http://www.4wd.com/==
 
  
===Cargo Hitch mount racks===
+
Logan Utah vendor
 +
 
 +
http://www.evsource.com
 +
 
 +
British Columbia company
 +
 
 +
http://www.azuredynamics.com/
 +
 
 +
EV power systems South Carolina
 +
 
 +
http://www.evpowersystems.com/
 +
 
 +
http://www.jeepworld.com/
 +
 
 +
http://www.ddmotorsystems.com/
 +
 
 +
http://www.metricmind.com/
 +
 
 +
http://www.revoltevc.com/
 +
 
 +
 
 +
 
 +
http://www.electric-cars-are-for-girls.com/
 +
 
 +
http://e-volks.com/gpage1.html
  
http://www.4wd.com/productdetails.aspx?partID=60980
 
  
http://www.4wd.com/productdetails.aspx?partID=10580
+
http://www.diyelectriccar.com
  
http://www.4wd.com/productdetails.aspx?partID=54149
 
  
http://www.4wd.com/productdetails.aspx?partID=54146
+
http://rebirthauto.com/
  
http://www.4wd.com/productdetails.aspx?partID=54147
 
  
http://www.4wd.com/productdetails.aspx?partID=54148
+
[[TF_EV]]

Latest revision as of 04:42, 19 May 2013

Budget

Cost Item
7,000 http://hpevs.com/catalog-ac-75-27.26.htm 96 Volt AC75 motor + controller kit
4,000 http://www.canev.com/batteries.php Lithium batteries > 30 3.2 volt 300 Ah
3,000 Battery Management
850 adapter plate

Design

ac50

Probably use two AC 50 motors in series with separate packs

Midvale Utah distributor $7454

http://www.electriccarpartscompany.com/650-Amp-HPEVS-AC-50-Complete-AC-Vehicle-Kit_p_143.html

Cost Item
4300 AC 50 motor, controller, & harness from http://www.electricmotorsport.com/store/ems_ev_parts_motors_ac50.php
6300 96 volt, 100 Ah lithium battery pack http://www.electricmotorsport.com/store/ems_ev_parts_batteries_lpf_gbs_kit96.php


http://hpevs.com/

Motor- transmission adapters

See http://www.canev.com/KitsComp/Components/Adapter%20page.htm


Battery Management system (BMS)

Orion and Elithion are two polular controller manufacturers


http://elithion.com/comparison.php

ac75 ac150

http://hpevs.com/catalog-ac-75.htm


http://www.acpropulsion.com/


Liquid cooled lcm150

http://www.acpropulsion.com/datasheet/LCM-150.pdf


Forum for AC75

http://www.diyelectriccar.com/forums/showthread.php/hpevs-ac-75-data-79186.html

References

EV discussion list

http://www.evdl.org/index.html

http://avt.inel.gov/index.shtml

Builds by others

Kris motors

http://krissmotors.blogspot.com/

Eric Tischer's AC conversion

http://etischer.com/awdev/

http://www.electric-cars-are-for-girls.com/ac-conversion.html

http://www.evalbum.com/3399

http://www.evalbum.com/1095

http://www.evalbum.com/2101

CRx (1989-1991) Honda CRX/del sol

http://www.evalbum.com/1250

http://www.evalbum.com/1648

http://www.evalbum.com/3505

http://www.evalbum.com/2778

http://www.evalbum.com/2222


VWs

http://www.evalbum.com/684

http://www.evalbum.com/3254

http://www.evalbum.com/556

http://www.evalbum.com/2728

GEO tracker

   * Ground clearance: 7.9 in.
   * Curb weight: 2238 lbs.
   * Wheel base: 86.6 in.

http://eastidaho.craigslist.org/cto/2378173601.html

Toyota MR2 (1985-1989)


http://www.amphibike.org/index.cgi?page=pages/3_wheels/mr2

Electric Power plants

Below are the motors and generators you want for the EV

http://www.industry.usa.siemens.com/drives/us/en/electric-drives/hybrid-drives/Documents/elfa-components-data-sheets.pdf

Electric conversion kit

ReVCon

http://www.revconversions.com/electric_vehicle_conversion_products-jeep.htm


REVConversions is the only conversion company that has been able to successfully convert 4-wheel drive all-electric Jeep Wranglers that function and shift properly in every gear in both high & low range driving modes.

The first Wrangler conversion that was made for the Jeep Tour Industry retains the automatic transmission. The 160-volt drive system (twenty 8-volt batteries) drives a Warp-11 DC motor with our own proprietary forced-air cooling system.

The first Wrangler conversion kits are available for immediate delivery.

For Pricing and to Order: Contact Us


Verde Sustainable Energy, Inc. Ian Wickson (President) Bruce Berkson (General Manager) Phil Brown (Production Manager) 250 Cherry St., Suite B Cottonwood, AZ 86326


Office: (928) 282-0101

   Cell: (928) 254-0196
    Fax: (928) 649-0102

Email Us: phil@revconversions.com


CANEV

http://www.canev.com/KitsComp/Universal%20Kit/universal%20kit.htm

Motors & Controllers

Spec siemens-1pv5135-ws18 [[1]] mes-200-330 AC-50 [2][3] Baldor TE MR-50 2.5 L 4 cyl AMC 150 mopar
Inverter DC voltage (Volts) 520-900 185-400 130 max 72-96
Rated RPM 3500 2850 3500
Max RPM 10,000 9,000 6500 5000
Rated Continuous Power (kW) 61 40 (400 V 100 A or 200 V 200 A) 20 (130 VDC 650 A; 15 Hp)
Peak Power (kW) 150 87@5000 RPM 49 (67 Hp) @ 3000 rpm (50 hp) 60 kW (80 bhp x 0.75) @ 3000 rpm
Rated Torque (Nm)@phase current (A) 160@145 130 (150 ft lbs) (150 ft lbs)
Peak Torque (Nm)@phase current (A) 370 @ 300 300 110 ft-lb 183@ 3500 RPM
Max Current (A) 400 peak / 282 RMS 362
Weight (kg) 90 80 115 lbs 490 lb
Diameter (cm) 24.5 23.5
Length (cm) 42.5 47.5
Cost (USD) 9161 7138 4620 (4390) 4700 + 7700
AC power inverter ? MES TIM-600 ($5995) Curtis Regen model 1238-7601 Curtes Regen 1238R-7601
HP/Torque curve SimensAC TP.gif Mes 200-250 TP.jpg AC50 MotorSpecs.png Torque curve 89 2.5LAMC150.png

http://www.azuredynamics.com/products/force-drive/documents/AC90_DMOC645ProductSheet.pdf

http://www.azuredynamics.com/products/force-drive/documents/AC55_DMOC445ProductSheet.pdf

The AC motors have controllers which convert a DC source to an AC voltage with variable frequency to drive the motor speed. Motors work best at higher DC voltages.


EV AC motor Performance Comparison.png


File:EV AC motor Performance Comparison.xmgrace.txt


Open source AC motor controller blog


http://ecomodder.com/forum/showthread.php/paul-sabrinas-cheap-3-phase-inverter-ac-controller-10839.html

Luminati configuration

The engine compartment includes: +99 Thundersky 4.25 volt lithium iron phosphate batteries (TS 100AH) = approx. 32 Kwh +200 horsepower MES DEA electric motor: MES 200-330 induction (compare to Chevy Volt’s 149 HP motor) + Manzanita Micro PFC-40 (220v, 40 amp off board charger will charge the car overnight) charger + MES-DEA – TIM600 (100kW) inverter

DC power supply

440 AC input with 60 kW output (0-600 Volt , 0-100 A)

A 1500 lb box with dimensions 44 x 27 x 33 " ( 4 ' x 2' x 3')

http://www.us.tdk-lambda.com/hp/product_html/emhpower.htm

Metric Mind motors

http://www.metricmind.com/category/ev-ac-drive-systems/ev-motors/

http://www.metricmind.com/products/mes-200-330/

http://www.metricmind.com/products/siemens-1pv5135-ws18/

90 HP Siemens AC motor for Ford Ranger

http://www.commoditiesrecoverycorp.com/electricmotors.htm

http://www.zuglet.com/ev/fordsiemens/fordsiemens.html

Electric Motor Sport

http://www.electricmotorsport.com/store/ems_ev_parts_motors_ac-induction.php

Kosov AC motors

http://kostov-motors.com/tractionmotors/kostovevmotors%28ac-dc%29/

AC propulsion

http://www.acpropulsion.com/products-drivesystem.html

Warp -11

The 160-volt drive system (twenty 8-volt batteries) drives a Warp-11 DC motor.

20 batteries => Try the US battery 8VGC-XC (Length : 10-1/4” (260mm) Width : 7-1/8” (181mm) Height : 11-1/4” (286mm) )$150 each => $3000; change after 650 cycles; assuming about 80 miles/charge => 650 * 80 < 52,000 miles => 17 miles/$

If 30 mpg * 1g/$4 = 7.5 miles/$

Cost of electricity to charge batteries at $0.1 per kWh (in idaho its 7 cents)


kWh = 10^3 Watt * hrs = 3.6 \times 10^6 Joules = 3.6 \times 10^6 Coul * Volts


130 Amp*hrs = 469,000 Coul 160 Volt * 469,000 Coul = 7.5 \times 10^7 Coul * Volt = 1 cycle of charge

cost per charge = $0.1 * 3.6 \times 10^6 / 7.5 \times 10^7 = $0.005 ??? too cheap must be mistake somewhere


$2,673.75 http://www.revoltevc.com/motors/warp11.html


TransWarp-11 $3,105.00 http://www.revoltevc.com/motors/transwarp-10.html

(72 Volts*453 Amps= 33 kWatts =43.7 HP of power ; using 18, 8 Volt batteries => 227 Amps)

$2,175.00 controller http://www.revoltevc.com/controllers/netgain-controlls-warp-drive-dc-controller.html

$145.00 gas pedal http://www.revoltevc.com/controllers/netgain-controls-hepa.html

$300.00 liquid coolant system http://www.revoltevc.com/controllers/netgain-controls-liquid-cooling-kit.html

DC-9

The advance DC-9 that was used in this application is about $1550. The only alternative to that motor is the Netgain WarP-9 which is $1675.00. The Curtice controller is about $1500. There are others but not really sure about prices and specs. There are very few that can handle the high voltage and current that an EV conversion has. There is one controller that is the Rolls Royce of controllers Called the Zilla2000 with Hairball interface. These monsters can handle far more current and voltage than the Curtice can, it can also be programed to function on a given curve and limit the maximum current that it will allow through it. This controller is around $6000 with the interface. There really isn't a cheap way to do it so the thing will be drivable and reliable.

Zilla

Zilla motor controllers. He has an electric 914 that has 800ftlbs of torque at zero RPM

Soliton1

http://www.evolveelectrics.com/Soliton1.html

Batteries

Zinc-air

http://www.electric-fuel.com/evtech/index.html


Nano phosphate ext

http://www.a123systems.com/products-systems-energy-core-pack.htm

http://www.a123systems.com/lithium-ion-battery-technology.htm

http://www.sfgate.com/cgi-bin/article.cgi?f=/g/a/2012/06/12/bloomberg_articlesM5BRQP0UQVI901-M5IU0.DTL

Lithium

http://www.valence.com/


A123 system battery packs(currently not selling packs To consumers)

http://www.a123systems.com/products-systems-energy-core-pack.htm


lithium iron phosphate

Recharging in minutes not hours?

http://www.tgdaily.com/general-science/41686-mits-revamped-li-ion-batteries-fully-recharge-in-seconds-not-hours

http://ceder.mit.edu/


http://electriccarinternational.com/

http://kostov-motors.com/tractionmotors/kostovevmotors%28ac-dc%29/lithiumbatteriesbmsandchargers/

http://lithiumpros.com/products/

http://www.valence.com/energy-storage/xp-12v-19v-lithium-phosphate-battery-module

Thunder sky (now called Winston Battery) 4.2 Volt

http://thebackshed.com/basiclynatural/ViewItem.asp?CL1=17&CL2=53&id=49

http://ev-power.com.au/webstore/

http://ev-power.com.au/webstore/index.php/12v-4-cell-100ah-lfp-battery-module.html


http://elitepowersolutions.com/packages.html

Lead

Typically it takes 15-20 lbs of lead to achieve 1 mile in range. A Rule of Thumb is that 1/3 of the EVs weight should be batteries; the other 2/3 represents dead weight (i.e. frame, suspension, body, motor, etc).

If you want to have 1/3 to 1/2 of the finished weight in fuel; then the initial curb weight of the vehicle should be less than 3000 lbs. The 1991 Jeep Wrangler Renegade (YJ) has a gross vehicle weight of 3090 lbs to 4700 lbs.

http://www.acterra.org/ev/files/batteries_1.html


Try the US battery 8VGC-XC $155

Generator driven EV

http://www.polardcmarine.com/polarpower/wp-content/uploads/2010/07/26Kw_Brochure_LowerRES.pdf


See solution #2

http://www.evconsultinginc.com/articles/hybridizing_dc_system.html


http://www.diyelectriccar.com/forums/showthread.php/generator-direct-power-ev-distance-48794.html

http://www.evconsultinginc.com/articles/hybridizing_dc_system.html

http://www.bladonjets.com/

EV racing

http://www.plasmaboyracing.com/

http://www.killacycle.com/


http://www.thecoreiv.com/products/25.html?Itemid=15

Portable generators

The generator should be rated to at least 40 kW

http://catalog.ameritempltd.com/viewitems/temporary-power/industrial-standby-generators?

PTO units

http://www.electricgeneratorsdirect.com/power/40-59-kw-540-rpm-pto-generators.html


http://www.voltmasteramerica.com/products/tractor1800.htm

http://www.hardydiesel.com/pto-generators/dl/Winco_PTO_Generator_Specs_W11PTOS.pdf

Diesel engines for PTO

YANMAR DIESEL ENGINE 90hp

http://www.dbsupplyco.com/

Diesel Generators

Perkins 4.236 Diesel Powered Generator $6750

http://www.perkins.com/

Diesel Electric

Phone: [801] 972 1836

Address: 652 West 1700 S,Salt Lake City 84104 Utah

Model: ElectroPak: complete unit with radiator ...

Power Zone Equipment (Center, Colorado near Alamosa)

http://www.powerzoneequipment.com/

Industrial Generators from Trans Atlantic Diesels, Inc


http://www.dieselserviceandsupply.com/Used-Generators

Gasoline Generators

$3k

http://www.northerntool.com/shop/tools/product_200379773_200379773

Maybe 2 17 kW generators

http://www.electricgeneratorsdirect.com/power/10000-plus-watt-portable-generators.html

trifuel

http://www.trexgenerators.com/Winco-HPS12000HE-10800-Watts-TriFuel-Honda-Engine-p-1053.html

Example

http://www.electric-cars-are-for-girls.com/portable-generator.html

Accessories

charging connector

http://en.wikipedia.org/wiki/SAE_J1772

Hitch

http://www.etrailer.com/hitch-1989_Jeep_YJ.htm

rear bumper with hitch

http://cgi.ebay.com/ebaymotors/JEEP-WRANGLER-YJ-TJ-REAR-BUMER-HITCH-RECEIVER-_W0QQcmdZViewItemQQhashZitem3f0a0f8ed5QQitemZ270751731413QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories


trailers

http://www.fthr.com/flatbed-commercial-utility-trailers/

Removing vaccum from transfer case

Wrangler Forum

http://www.wranglerforum.com/f8/vacuum-shift-motor-inexpensive-fix-87568.html


From Wrangler Forum

http://www.wranglerforum.com/f8/by-passing-frt-diff-4wd-vacuum-78334.html



1. jack up right frt. tire and place on jack stand (easier if not done on a day that snow is not packed on your jeep...lol)

2. unplug vacuum lines from the shift motor actuator and cap off you will not need them any more .

3.remove the four bolts holding shift motor on and remove it (don't forget to have a pan or towel on the floor to catch the very amount of lube that will come out)

4.now look at the axle see how the collar slides over to connect the two axle's together? you might have to turn the right tire a little as you use your finger to slide it to left all the way as the splines line up now your frt. diff is locked into fwd. ( that's a good thing for a jeep)

5.now take apart the shift motor.take a marker and put a dot on one side of the fork and a dot on the matching side of the housing so you will remember what way the fork faces( trust me it saves time..lol) remove the two e-clips holding the shift fork shaft in place and pull shaft out. discard everything but the shaft,fork and big e-clip

6.now put the shaft with the fork back in the housing (no e-clip yet) and move the fork all the way to the right that is where it is when the 4wd is locked in ( remember the collar you slide to the left to lock the axle's together?)

7. now get a spring or fuel line (like i did) and cut it to take up the space on the shaft so that the fork can not move to the right ( and yes the spring or hose needs to fit over the shaft and I am sorry i did not measure the length or i.d for ya but heck you need to do a little of the work yourself) tip: if you use a piece of hose it needs to be fuel and oil resistant ( mine has been set this way for two years)

8.after you get the spacer cut right put in the e-clip so the shaft won't come out.

9. reinstall on the diff. using a little gasket sealer or a new gasket and your almost done. top off the lube if you feel like the little bit that came out is a bad thing.

10. you are now done and have a much improved 4wd set up. you will not notice a drop in mpg, no change in handling ( transfer case disconnects the frt. drive). what you will feel is a good feeling knowing your frt. axle really is locked in when it's needed ( yep even when it is -7 degree's like it is here to day)

Vendors

Logan Utah vendor

http://www.evsource.com

British Columbia company

http://www.azuredynamics.com/

EV power systems South Carolina

http://www.evpowersystems.com/

http://www.jeepworld.com/

http://www.ddmotorsystems.com/

http://www.metricmind.com/

http://www.revoltevc.com/


http://www.electric-cars-are-for-girls.com/

http://e-volks.com/gpage1.html


http://www.diyelectriccar.com


http://rebirthauto.com/


TF_EV