Worlds first, registered industrial EV conversion

Post up a thread for your EV. Progress pics, description and assorted alliteration
Post Reply
User avatar
a4x4kiwi
Senior Member
Posts: 772
Joined: Thu, 03 Jan 2008, 19:04
Real Name: Malcolm Faed
Location: Australia
Contact:

Worlds first, registered industrial EV conversion

Post by a4x4kiwi » Fri, 20 Mar 2009, 16:21

I began this planing this project after visiting the AEVA field day in October 2007. After much planing and calculating in Excel, I started purchasing parts (the motor) in December 2007.

It took a while to find a vehicle that would suit. I looked at Toyota Town Aces, Suzuki Carrys Toyota SBVs and finally settled on a Toyota Hilux extra cab ute in April 2008. My requirements were to carry 360kg of SLA batteries + inverter and have 4 seats (for kids) without significant chassis modification.

It was cheap for the model, but reasonably tidy. Some rust that needed dealing to but OK. This model is popular with young guys and this one had been painted black and had dark tinting, so I had to de-bogan it as well.

To get to the point, I finally got it registered on the 7th of March.

I am very happy with its performance on road. Thanks to Tuarn (acmotor) for your inspiration in leading the way, despite me bing first to register. Image

The tweaking and fiddling with settings took a while but got there in the end. It even has regeneration which is necessary in my hilly area.

If there are any other registered industrial AC conversions around, do challenge my "subject" as I would be interested to know more about theirs, and concede to a lesser accolade of Australia or NSW.    Image

My blog (link below) has the build details.
Last edited by a4x4kiwi on Tue, 07 Apr 2009, 06:00, edited 1 time in total.
Silicon is just sand with attitude.

Blog: http://malfunction.faed.name

User avatar
acmotor
Senior Member
Posts: 3594
Joined: Thu, 26 Apr 2007, 03:30
Real Name: Tuarn
Location: Perth,Australia

Worlds first, registered industrial EV conversion

Post by acmotor » Fri, 20 Mar 2009, 19:12

Great work Mal, Image

This will be interesting. I think you will be without challenge to the title ! I shall scrutineer !

Off the shelf industrial motor and industrial controller, 3 phase with regen, direct drive. I guess we can accept any challenger who couldn't figure out how to unbolt the tooth box ! Image

iMiEV MY12     105,131km in pure Electric and loving it !

User avatar
Thalass
Senior Member
Posts: 741
Joined: Sun, 12 Aug 2007, 07:29
Real Name: Ben Rypstra
Location: Perth, WA, AU

Worlds first, registered industrial EV conversion

Post by Thalass » Tue, 24 Mar 2009, 20:16

This is very encouraging! I want to do the same sort of thing with my Brumby, so now I can use your Hilux as a reference project! haha
I'll drive an electric vehicle one day.

User avatar
woody
Senior Member
Posts: 1711
Joined: Sat, 21 Jun 2008, 02:03
Real Name: Anthony Wood
Location: Mt Colah

Worlds first, registered industrial EV conversion

Post by woody » Wed, 08 Apr 2009, 07:05

So, um, acmotor, haven't you quite got that Red Jeep thingo inspected yet?

Mal, could you give us a rough breakdown of your AU$14,000 to the nearest $500? e.g.

Donor: $4000
Motor + Sealed Bearings: $500
Greensavers including Shipping + Import: $3000
Chargers
BMS
Custom Tailshaft
Battery Tray + Lid
Motor Mount + Speed Pickup
Engineering
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack

User avatar
acmotor
Senior Member
Posts: 3594
Joined: Thu, 26 Apr 2007, 03:30
Real Name: Tuarn
Location: Perth,Australia

Worlds first, registered industrial EV conversion

Post by acmotor » Wed, 08 Apr 2009, 07:34

woody, EV conversion 101
Spend more money on the donor or you will spend all your time fixing it not the conversion part !
I am still working with my DPI approval engineer. The eparts are fine but..
New leaf springs, brake shoes and wheel cylinders, front steering knuckle seals, wipers, window winder mechanisms, door locks, ign key assembly (key must not be removable when on)   etc etc. It has taken months. Getting close now.

Mal is first to rego an industrial AC in the world (Still no challenger)(I only built one first) Healthy competition ! Image
iMiEV MY12     105,131km in pure Electric and loving it !

User avatar
Electrocycle
Senior Member
Posts: 985
Joined: Sun, 19 Oct 2008, 20:23
Real Name: Andrew
Location: Sydney
MSN: dumhed@dumhed.com
Contact:

Worlds first, registered industrial EV conversion

Post by Electrocycle » Thu, 16 Apr 2009, 01:29

I can confirm that this car does actually work!
It makes an excellently sci-fi electro-turbine sound too :)

There are certainly some kinks to iron out in the whole industrial VFD controller system, but with something a bit more EV specific it'd be getting close to average-user friendly.
The Engine Whisperer - fixer of things

PLB-389
Noobie
Posts: 9
Joined: Thu, 23 Apr 2009, 00:15
Real Name: Peter
Location: Sydney
MSN: dvspeter@hotmail.com

Worlds first, registered industrial EV conversion

Post by PLB-389 » Thu, 23 Apr 2009, 01:02

I don't know about registered, but the Catholic University of Chile converted a ute (the chevrolet version of a Holden Rodeo) to EV back in 2000/2001 or before. One of the photo's I've seen clearly shows a number plate as well...maybe Australian first?

Check out:

Ortuzar, M and Dixon, J. "Ultracapacitors + DC-DC Converters in Regenerative Braking System", IEEE AESS Systems Magazine, August 2002.

Oh and btw, hi everyone, I'm new to the forums...
Cpt. Pete (Barge Pilot)

User avatar
a4x4kiwi
Senior Member
Posts: 772
Joined: Thu, 03 Jan 2008, 19:04
Real Name: Malcolm Faed
Location: Australia
Contact:

Worlds first, registered industrial EV conversion

Post by a4x4kiwi » Thu, 23 Apr 2009, 01:17

Welcome to the forums Cpt. Pete.

Excellent article, and innovative way to use the ultracaps.

Do you know happen to know if the conversion was using industrial components (motor and VFD)?

I only skimmed the article but it would seem it is based on a brushless DC motor and a custom controller.
Silicon is just sand with attitude.

Blog: http://malfunction.faed.name

antiscab
Senior Member
Posts: 2322
Joined: Mon, 26 Nov 2007, 05:39
Real Name: Matthew Lacey
Location: Perth, WA

Worlds first, registered industrial EV conversion

Post by antiscab » Thu, 23 Apr 2009, 01:22

gday pete,

welcome to the AEVA

heres a link to that article

Matt
Matt
2017 Renault zoe - 25'000km
2007 vectrix - 156'000km
1998 prius - needs Batt
1999 Prius - needs batt
2000 prius - has 200 x headway 38120 cells

User avatar
coulomb
Site Admin
Posts: 3572
Joined: Thu, 22 Jan 2009, 20:32
Real Name: Mike Van Emmerik
Location: Brisbane
Contact:

Worlds first, registered industrial EV conversion

Post by coulomb » Thu, 23 Apr 2009, 01:47

a4x4kiwi wrote:Do you know happen to know if the conversion was using industrial components (motor and VFD)?
No, it's a brushless DC;
Image

Also 312V pack. So not industrial.
Learning how to patch and repair PIP-4048 inverter-chargers and Elcon chargers.

PLB-389
Noobie
Posts: 9
Joined: Thu, 23 Apr 2009, 00:15
Real Name: Peter
Location: Sydney
MSN: dvspeter@hotmail.com

Worlds first, registered industrial EV conversion

Post by PLB-389 » Thu, 23 Apr 2009, 02:16

ahh apologies! This shows how new I am to the world of EV's! When I read industrial I thought as in the type of vehicle rather than the type of componentry! So the claim to fame still stands!
Cpt. Pete (Barge Pilot)

PLB-389
Noobie
Posts: 9
Joined: Thu, 23 Apr 2009, 00:15
Real Name: Peter
Location: Sydney
MSN: dvspeter@hotmail.com

Worlds first, registered industrial EV conversion

Post by PLB-389 » Thu, 23 Apr 2009, 02:19

which actually, come to think of it is quite an odd thought considering that its well known that electric traction has been moving buses and vans for a lot longer than it has small vehicles...
Cpt. Pete (Barge Pilot)

User avatar
acmotor
Senior Member
Posts: 3594
Joined: Thu, 26 Apr 2007, 03:30
Real Name: Tuarn
Location: Perth,Australia

Worlds first, registered industrial EV conversion

Post by acmotor » Thu, 23 Apr 2009, 03:13

Hi PLB-389 and welcome.
No apology required. "off the shelf industrial" catches many people out.

The "industrial" experiment started out of frustration that so many EV conversions were Series DC motors. Relatively old design, low tech, no regenerative braking (some kid themselves). Yet all the upmarket experiments and commercial prototypes (and production like tesla) were specialist AC (which is what a brushless DC is in reality).
The cost of the specialist AC motors e.g. AC propulsions AC150 is so high.
Yet the industrial world has had 3 phase inductions motors and VFDs (variable frequency drives) for many years. There are new and second hand parts all over the world.
I bit like a poor mans Siemens or azure AC system, and it works.

This little experiment was back in Dec 2005
tiny AC motor
...and was only put up on evalbum later just to show it was possible.
Mal has rightly earned the World's first registered industrial (motor and controller) EV conversion title. AND WILL UPDATE HIS EV ALBUM LISTING VERY SOON !!! Hint Mal.

The higher battery pack voltages and special tuning are not for everyone but it is another option for EV convertors. Image
iMiEV MY12     105,131km in pure Electric and loving it !

PLB-389
Noobie
Posts: 9
Joined: Thu, 23 Apr 2009, 00:15
Real Name: Peter
Location: Sydney
MSN: dvspeter@hotmail.com

Worlds first, registered industrial EV conversion

Post by PLB-389 » Thu, 23 Apr 2009, 04:28

Thanks for the welcome! I suppose I'll get used to the nuances of EV talk as I spend more time here. Interestingly enough we've a LOT of industrial motors lying around at work (single phase, 3 phase, AC, DC...the lot) and I've often thought about whether or not they could be used for an EV, but not far enough to actually investigate it. I should probably introduce myself properly...I'll do that in another thread somewhere in a minute!
Cpt. Pete (Barge Pilot)

User avatar
a4x4kiwi
Senior Member
Posts: 772
Joined: Thu, 03 Jan 2008, 19:04
Real Name: Malcolm Faed
Location: Australia
Contact:

Worlds first, registered industrial EV conversion

Post by a4x4kiwi » Thu, 23 Apr 2009, 06:24

@acmotor. I updated my EVAlbum page last week. Image
Silicon is just sand with attitude.

Blog: http://malfunction.faed.name

User avatar
a4x4kiwi
Senior Member
Posts: 772
Joined: Thu, 03 Jan 2008, 19:04
Real Name: Malcolm Faed
Location: Australia
Contact:

Worlds first, registered industrial EV conversion

Post by a4x4kiwi » Thu, 23 Apr 2009, 06:27

Silicon is just sand with attitude.

Blog: http://malfunction.faed.name

User avatar
acmotor
Senior Member
Posts: 3594
Joined: Thu, 26 Apr 2007, 03:30
Real Name: Tuarn
Location: Perth,Australia

Worlds first, registered industrial EV conversion

Post by acmotor » Thu, 23 Apr 2009, 06:58

Mal,
It still says "(under construction)" at the top. Image so I didn't look further !

Re ultracap article.
Yes, that ultracap application is interesting, but 84% x 87% = 73% bidirectional efficiency limits the viability.

Better to use the ultra caps in my idea previously posted...

Image

Ultra caps are used (cycled) 100% of charge voltage = most efficient use of ultracap.
Gentle main pack charge during regen.
Only requires one diode. (could be FET or IGBT for flexible control) Image

edit: spelyn
Last edited by acmotor on Wed, 22 Apr 2009, 21:00, edited 1 time in total.
iMiEV MY12     105,131km in pure Electric and loving it !

User avatar
a4x4kiwi
Senior Member
Posts: 772
Joined: Thu, 03 Jan 2008, 19:04
Real Name: Malcolm Faed
Location: Australia
Contact:

Worlds first, registered industrial EV conversion

Post by a4x4kiwi » Thu, 23 Apr 2009, 07:40

Arrrg I though I got rid of the under construction. I will try and figure out how to change it.

The diode system is elegant simplicity.

FWIW, here is a better copy of the report with more detail and nice graphs http://www2.ing.puc.cl/power/paperspdf/dixon/51a.pdf
Silicon is just sand with attitude.

Blog: http://malfunction.faed.name

User avatar
a4x4kiwi
Senior Member
Posts: 772
Joined: Thu, 03 Jan 2008, 19:04
Real Name: Malcolm Faed
Location: Australia
Contact:

Worlds first, registered industrial EV conversion

Post by a4x4kiwi » Thu, 23 Apr 2009, 15:30

I sorted out the 'under construction' banner on evalbum. You have to contact the webmaster to have it removed.


Silicon is just sand with attitude.

Blog: http://malfunction.faed.name

User avatar
coulomb
Site Admin
Posts: 3572
Joined: Thu, 22 Jan 2009, 20:32
Real Name: Mike Van Emmerik
Location: Brisbane
Contact:

Worlds first, registered industrial EV conversion

Post by coulomb » Thu, 23 Apr 2009, 15:49

a4x4kiwi wrote: @acmotor. I updated my EVAlbum page last week. Image


Perhaps you could put the URL on your blog page. So others don't have to search till then: http://www.evalbum.com/1687
Learning how to patch and repair PIP-4048 inverter-chargers and Elcon chargers.

User avatar
a4x4kiwi
Senior Member
Posts: 772
Joined: Thu, 03 Jan 2008, 19:04
Real Name: Malcolm Faed
Location: Australia
Contact:

Worlds first, registered industrial EV conversion

Post by a4x4kiwi » Thu, 23 Apr 2009, 16:09

Thanks Coulomb. Good tip. I have done, and also in my sig.
Silicon is just sand with attitude.

Blog: http://malfunction.faed.name

User avatar
acmotor
Senior Member
Posts: 3594
Joined: Thu, 26 Apr 2007, 03:30
Real Name: Tuarn
Location: Perth,Australia

Worlds first, registered industrial EV conversion

Post by acmotor » Thu, 23 Apr 2009, 18:30

Even I like my ultracap circuit better !
I'll start its own thread, see what response we get. Image
New topic
iMiEV MY12     105,131km in pure Electric and loving it !

Post Reply