TF Project JeV 1989

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			Torque curve

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.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