Woody's 1963 Ford Cortina

Post up a thread for your EV. Progress pics, description and assorted alliteration
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woody
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Woody's 1963 Ford Cortina

Post by woody » Sun, 27 Dec 2009, 06:16

The Cortina moved under it's own (ICE) power today for the first time in 3 years. So I guess that's as good a starting point to declare as any.

This post will be replaced with table of contents as per the guidelines, but for now will just be a sketch of what will go here.

cheers,
Woody

Aims:
1. Fun to drive
2. Practical for daily use
3. Minimal modifications to structure
4. Roughly break even dollarwise in the long term, discounting own time spent

Why this car:
1. We have owned it since 1994 and love it
2. It is light (800kg)
3. No ICE-powered accessories (heater, brake booster, steering, aircon) - only have to make the car go
4. easy to improve on performance (0-100 in 26 seconds when new)
5. rear wheel drive, front engined

The parts:
1. Industrial A/C components like acmotor, a4x4kiwi, Johny
2. ABB 132-316HSE 4 pole 240V 50Hz motor (ordered)
3. Industrial VFD around 55kW e.g. Telemecanique ATV71-HD55N4
4. 10-20 Ah of LiFePO4 200-225S 1-2P e.g. Headway, EVPST, TS

The plan:
1. Emotor in engine bay, partially in transmission tunnel
2. Direct to diff drive via modified sliding spline tailshaft - no gearbox
3. Batteries (75-150kg) under boot and/or behind wheels. Fuel tank in boot floor bolts out, leaving hole for battery access.
4. VFD under parcel shelf behind rear seats.
5. Split batteries into safe voltages, maybe 48-72V with contactors.
6. Charge either 1 fat charger in parallel via diodes or multiple chargers of low voltage, each charging 1 or more packs.
7. BMS - leaning towards Nevilleh BMS because micro is flexible.
8. Range Extender Trailer- original ICE + 2pole ACIM + small VFD

The timeline (slow):
1. Plan to re-register car running original ICE ASAP
2. Work out when the rest can happen, I plan to have it registered during conversion so that I can road test it legally.

Progress (slow)
21/12/2009: ABB 132-316 HSE is ordered, I expect sometime in the first half of next year.
26/12/2009: Car is running again under ICE power, some brakes siezed, thermostat probably stuck (overheats real quick)
27/12/2009: thermostat replaced, radiator flushed - seems OK now.
4/1/2010: had planned to register by now - brakes + steering fixed but rust is non-trivial
6/2/2010: started rust work on dodgy passenger side sill

Edits:
2009-12-27: added up range extender trailer details
2010-02-09: progress 4/1 + 6/2
Last edited by woody on Mon, 08 Feb 2010, 18:18, edited 1 time in total.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack

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Post by coulomb » Sun, 27 Dec 2009, 15:50

Congrats, Woody!

So you're keeping the original ICE, since the whole car is so light, and will be using a 2-pole induction machine as a generator for range extension? Neat!

I couldn't help a little AC motor comparison here; sorry I couldn't find a reliable catalogue with all 3 motors in it (the Combined Asia Region seems to disagree with others over important details).

Image

The heavier motor is the most efficient, though it's extra 66 kg (compared to the other 22 kW motor) adds some 5% to the weight of a 1300 kg vehicle, or 3.3% to a 2000 kg vehicle. For 2.1% more efficiency, it's not looking such a bad deal, considering that regen reduces the weight penalty somewhat.

It's interesting that the 4-pole motors have heavier (higher inertia) rotors. Woody's motor is ~~ 30/22 ~= 1.3 times more powerful at 2900 RPM; scaling the rotor would yield 0.033, still only 65% of the 4-pole's inertia. Acmotor's is almost 9x the inertia.

I'm intrigued that our 22 kW has the highest power factor of these motors. So we'll be using a slightly greater proportion of inverter current to power the wheels, rather than energise the field. Of course, that situation could well change when the motor is overloaded.
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woody
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Post by woody » Sun, 27 Dec 2009, 22:17

coulomb wrote: Congrats, Woody!

So you're keeping the original ICE, since the whole car is so light, and will be using a 2-pole induction machine as a generator for range extension? Neat!
I've clarified a bit more above, I want to mount the original ICE, radiator, fuel tank, etc on a small trailer together with the small 2 pole and VFD (15kw?), plug into the 600V bus and use it for longer trips. This will keep the ICE servicable and be cheap / easy / cool.
I'm intrigued that our 22 kW has the highest power factor of these motors. So we'll be using a slightly greater proportion of inverter current to power the wheels, rather than energise the field. Of course, that situation could well change when the motor is overloaded.
The power factor only holds for the nominal speed/load according to the ABB formulas - power factor goes up with load, but the VFD does tricky things like lowering V/F for better efficiency so who knows?
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack

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Post by acmotor » Sun, 27 Dec 2009, 23:19

Woody, great to see the 'member's machine' Keep us posted.

Coulomb, this is interesting comparison. The HO specs look good.

Can you add in the gearbox/adaptor plate weight and gearbox efficiency as these are telling factors when trying to compare DD to GB systems.
I think the overall weight will come closer though still be in the 2 pole favour, but the efficiency difference will be massivly in the 4 pole DD favour.

Ts/Tn has no relevance to EV use. Unless you plan to get the VFD setup wrong and pull 360A at 50Hz with locked rotor !!

BTW, the actual data for my 22kW from data sheet supplied with motor is...
(Ask for the 3 page technical data shhet that comes in .xls format from ABB)

Product          TEFC, 3-phase, squirrel cage induction motor               
Product code          3GAA 182 102-ADC               
Type/Frame          M3AA 180 L 4               
Mounting          IM1001, B3(foot)               
Rated output PN          22     kW          
Rated voltage UN          415     VD      ± 5 % (IEC 60034-1)     
Rated frequency fN          50     Hz      ± 2 % (IEC 60034-1)     
Rated speed nN          1475     r/min          
Rated current IN          39     A          
No-load current          14.5     A          
Starting current Is/IN          7.5               
Nominal torque TN          142     Nm          
Locked rotor torque TS/TN          2.8               
Maximum torque Tmax/TN          3.1               
Load characteristics (IEC 60034-2)     
Load % Current A Efficiency %Power factor
100     39      93.3        0.84
75     31      93.9        0.8
50     23      93.6        0.71
25       16        91.8       0.52
Maximum starting time from hot          15     s          
Maximum starting time from cold          27     s          
Insulation class / Temperature class          F / B               
Ambient temperature          40     °C          
Enclosure          IP55               
Cooling system          IC411 self ventilated               
Sound pressure level (LP dB(A) 1m)          63     dB(A)     at load     
Moment of inertia J = ¼ GD2          0.225     kg-m2          
Weight of rotor          61     kg          
Total weight of motor          161     kg          

Noteably, these 'world market' motors have many different spec numbers listed for different markets so close comparison may be difficult.

You guys have the lower voltage delta versions that should work out well.
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Post by Richo » Mon, 28 Dec 2009, 06:21

So what did they say was the lead time for the motor?

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Post by woody » Mon, 28 Dec 2009, 12:51

I think the quote said 6 weeks manufacturing + 8 weeks shipping.
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Post by Richo » Tue, 29 Dec 2009, 01:47

That seems better than before.
Maybe last years down turn has improved times.

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Post by woody » Tue, 09 Feb 2010, 05:15

Started some rust repairs on the weekend.
Flikr
Highly recommend not letting your car get rusty.

Edit: midnight grammar
Last edited by woody on Mon, 08 Feb 2010, 18:16, edited 1 time in total.
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Post by Johny » Tue, 09 Feb 2010, 15:19

Really great to see reverse entropy in progress.

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Post by woody » Mon, 01 Mar 2010, 20:33

Entropy reversal almost complete!
Image
Image
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Post by Squiggles » Mon, 01 Mar 2010, 22:58

Woody, are you using "zinc anneal" sheet for you repair panels? Looks a bit like it. I used to use it when I was keeping my X1/9 on the road and always wondered if it was the right material.

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Post by woody » Tue, 02 Mar 2010, 04:20

Squiggles - the inner sill and other dabbed bits were scraps from a dishwasher or similar - so probably what you said, but no real thought went into that on my part, it's just what we had!

The outer sill (dark grey primer) was bought as a pre-bent "Sill Repair Panel" from a cortina specialist in melbourne ($50).
The guard repair section (Black) was bought from a Sydney ford specialist for $75.

I did get a chance to lie under the car with a ruler, and have a good look at everything...

SOGOS (Sawn Off Gearbox Output Shaft) is getting legs as a motor - tailshaft interface because:
1) it's a BOGOS (Bolt Off ...)
2) includes gearbox mount
3) looks like enough length between BOGOS and steering to fit motor and coupler
4) other SOGOS advantages like speedo drive, sliding spline mean I don't have to get a custom tailshaft or fit the guts of an electronic speedo into my mechanical speedo.

Also there will be plenty of room under the bonnet for the motor and controller, or the motor and an Esky.

The column shift output has 3 cables, which I am led to believe are push-pull for 1st-2nd, 3rd-4th, and reverse. So I should be able to make something simple to keep the approximate feel of the column shift. My current plan is to use the gear lever for electric reverse, and the different gear positions will give different amounts of engine braking.
Last edited by woody on Mon, 01 Mar 2010, 17:27, edited 1 time in total.
Planned EV: '63 Cortina using AC and LiFePO4 Battery Pack

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Post by woody » Mon, 08 Mar 2010, 16:06

Quick Update: the car is re-registered and on the road under petrol power - much thanks to Electrocycle for lots of help on Thursday + Friday last week with brake dramas.

Blue slip, rego + drive to Wamberal (60km) on Saturday morning, return journey Sunday afternoon. No major dramas.
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Post by Johny » Mon, 08 Mar 2010, 22:11

Great! Are you going to leave it petrol for a while or start the rip-out soon?

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Post by woody » Mon, 08 Mar 2010, 23:19

I'm planning on gettIng all the bits I think I need first, get it all working as best I can outside the car, then pull it apart, possibly waiting for rego renewal if it's close.
Possible exception is batteries, I have 3 phase to my house.
I also have to fix up the drivers side doors, save up some pocket money, wait for ABB to build my motor, raise a family, etc. :-)
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Post by Johny » Tue, 09 Mar 2010, 02:38

Yes, that seems like a good way to go. I guess I have spent the last 18 months collecting bits and I thought I was going fast! This assembly stage is dragging but the house and family tends to take precedence, as it should.
Anyways, good to see that the Cortina has started it's new life.

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Post by Lester » Tue, 16 Mar 2010, 01:37

Drove behind you today in my ev and your car is in lovely retro shape....will be even better without the ICE! I knew it was you due to the nicely done rust repair.....

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Post by woody » Tue, 16 Mar 2010, 05:04

Lester wrote: Drove behind you today in my ev and your car is in lovely retro shape....will be even better without the ICE! I knew it was you due to the nicely done rust repair.....
I _really_ need to get some paint onto that...

Please honk + wave next time :-)

We'll have to invent an international hand signal for EV!
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Post by woody » Wed, 14 Apr 2010, 16:31

I chased up my motor supplier and my ETA is "pretty firm" as June 7th, so 12 weeks from now :-)
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Post by woody » Wed, 17 Nov 2010, 22:01

woody wrote: I chased up my motor supplier and my ETA is "pretty firm" as June 7th, so 12 weeks from now :-)
I am informed that my motor is now in Bangkok - should be here next week.

Final Order Details:

3GAA132007-HSE
MOTOR 18.5KW 4P M3AA132SMD
FOOT/FLG B35

HIGH OUTPUT DESIGN
M3AA132SMD 4 HO 18.5kw 110V DD, 220 VD, 50Hz,
+142 12 terminal connection
122 x 2.6 = 317Nm.
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Post by a4x4kiwi » Wed, 17 Nov 2010, 22:55

wahoo. :)
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Post by Johny » Thu, 18 Nov 2010, 14:05

woody wrote: - should be here next week.
Great - then the fun can start.

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Post by woody » Fri, 26 Nov 2010, 13:30

Motor is in the country (Control Techniques - Brisbane) and paid for!

Here is a progress photo showing my generator trailer and how much work I've been able to get done since I bought it.

Image
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Post by Johny » Fri, 26 Nov 2010, 14:44

Ha ha. It took me a moment to get it.

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Post by Speedily » Fri, 26 Nov 2010, 19:45

If you trim that the right way it would just about look like a generator on a trailer ;)

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