Help! Warp 9, sub 100kg car, ??Direct Drive??

Technical discussion on converting internal combustion to electric
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sauron_3746
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Help! Warp 9, sub 100kg car, ??Direct Drive??

Post by sauron_3746 »

Hi Everyone,

I have recently got my Suzuki Vitara (Sidekick or Samurai I think in the US) registered and on the road. But I have had a vibration issue in my coupling plaguing me. The engineer I hired has done a rubbish job aligning it. So I am looking at completely changing my drive system.

Currently I have a Warp 9 coupled to the stock Transfer, i.e. gearbox gone. The thought being that would give me 1:1 direct drive ratio, but also the 1:2.5ish low range for low speed maneuvering as to not stall/damage the motor.

Netgain tell me I should not use direct drive except for racing, or I should be running two motors. Given the size and capability of the Warp 9, and the low weight of my car, sub 1000kg (2100lbs), I thought it should be fine. I am running 144V system with 45 X 60Ah LiPo batteries. Netgain Warpdrive controller.

My question is, should I keep the transfer, fix the alignment and run the direct drive ratio for normal driving or am I going to damage my motor?

Or, should I seek some sort of gearbox and replace the transfer altogether?

My other thought was, I could remove the transfer and run true direct drive to lower the weight. I could then adjust the diff ratio if required.

Any thoughts or help is much appreciated.

Regards

Andrew
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Johny
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Help! Warp 9, sub 100kg car, ??Direct Drive??

Post by Johny »

Hi Andrew
My 2 cents worth.
I drive a direct drive AC conversion every day. It's voltaged and geared for power to about 75kmh and top speed with useful power to 115kmh (5000RPM). My controller only puts out 50kw. Take off is slow to about 20kmh but keeps up with traffic - after 20kph it's pretty quick. Motor is roughly equiv to a DC warp11.

Most motor heating is in stop.go traffic.
Unless you were geared for a top speed of around 70kmh I do not think a warp9 would last long.
My thoughts are you'll need 2 gears.
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Adverse Effects
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Help! Warp 9, sub 100kg car, ??Direct Drive??

Post by Adverse Effects »

i think he has 2 gears in the transfer case (4X4 high and low range i am guessing)

i carnt see a problem with it as long as for stop start sub 50Kmph low range is used

can that transfer box be shifted when you are driving or is it the type you have to be stopped to change it
sauron_3746
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Help! Warp 9, sub 100kg car, ??Direct Drive??

Post by sauron_3746 »

Thanks for the replies.

No, that's just it, gears cannot be changed whilst driving.
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Richo
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Help! Warp 9, sub 100kg car, ??Direct Drive??

Post by Richo »

Should be ok.
It's wouldn't be the first DD 9" motor.

Perhaps loosen the adaptor bolts between the motor and transfer case run the motor slow (wheels off the ground) and then do the bolts up.
This might take the misalignment out.
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Help! Warp 9, sub 100kg car, ??Direct Drive??

Post by antiscab »

what rpm is the motor doing at say 50kmh? or 100kmh?

DD on a warp 9 is ok - it's be done more than a few times
Matt
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Help! Warp 9, sub 100kg car, ??Direct Drive??

Post by mikedufty »

The dual range subaru boxes can be changed while driving, probably needs a clutch though.
sauron_3746
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Help! Warp 9, sub 100kg car, ??Direct Drive??

Post by sauron_3746 »

Some good ideas there. Ill have to go away and calculate the RPM at 50km/h then I will post. Richo, I like your idea about getting it off the ground and re tightening the bolts, I will definitely try that one. I have never hooked up the two temperature gauge wires, never looked into how they are used. But could I conceivably, hook them up to an in-cabin temp guage and monitor the temperature of the motor. Am I correct in suggesting if i do not breach a certain heat I should be fine?
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Help! Warp 9, sub 100kg car, ??Direct Drive??

Post by Richo »

sauron_3746 wrote: Richo, I like your idea about getting it off the ground and re tightening the bolts, I will definitely try that one.


This will only affect the motor to transfer case coupling.
As the motor runs it tries to self align when the bolts are loose.
This maybe difficult (not impossible) while the motor is horizontal.
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