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Sutho's DMC EV Electric DeLorean

Posted: Wed, 18 Jul 2012, 00:34
by Sutho
Hi All,

We recently completed a conversion of a 1981 DeLorean. Photos and details are below:

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The build incorporates the following major components:

- EVO Electric AFM140 Axial Flux Motor
- Tritium Wavesculptor 200 Motor Controller
- A123 Systems Nanophosphate Battery Modules
- Tritium BMS
- Brusa Charger
- Meanwell DC Converters


For more details and photos on the construction see:

DMCEV Facebook Page
EV Album Page
YouTube Video of Test Run

Cheers,
Sutho
Solar Power Australia

Sutho's DMC EV Electric DeLorean

Posted: Wed, 18 Jul 2012, 00:58
by weber
Great work guys! A work of art.

Sutho's DMC EV Electric DeLorean

Posted: Wed, 18 Jul 2012, 02:19
by htial
Wow...

Sutho's DMC EV Electric DeLorean

Posted: Wed, 18 Jul 2012, 03:05
by coulomb
I especially like the really shiny exhaust pipe ends, with the blue lights in them. In a subtle-as-a-brick way, it tells you that these pipes are not being used for the purpose of exhausting poisonous or greenhouse gases.

Sutho's DMC EV Electric DeLorean

Posted: Wed, 18 Jul 2012, 15:45
by PlanB
Flew my whirlybird up to Rafferty's on Lake Macquarie yesterday for lunch Brett. Had a good look down at Hillsborough Rd, I was gonna land if there was a DeLorean parked outside I swear! Looking forward to a squiz come Aug 18th, sounds sooo good on that Utube video.

Sutho's DMC EV Electric DeLorean

Posted: Wed, 18 Jul 2012, 20:27
by Sutho
Ha....that would have been good to see. :)

See you on the 18th.

Sutho's DMC EV Electric DeLorean

Posted: Thu, 19 Jul 2012, 01:43
by BigMouse
Great stuff! Are the A123 modules you got the pre-assembled blocks? I found a seller somewhere in Europe on Alibaba selling some and was curious about their condition and availability.

Sutho's DMC EV Electric DeLorean

Posted: Thu, 19 Jul 2012, 03:27
by Sutho
Yes....A123 7s3p modules.

In my opinion they are one of the best packaged cell options currently available, but they can't be sourced new for love or money. As such, the only option to obtain these modules is to run the gauntlet with online traders. This proved to be a very painful process for myself and others. I needed to purchase 50% more than I required to get enough modules of the right standard.

In the batches of modules I received, some were near new, some were older and many were damaged. Managed to pull together a good solid pack of the newer modules with no, or very little, damage.

The modules deliver 6C+ without breaking a sweat. They are capable of 20C.

Good luck!

P.s. Most were ex-Fisker modules with labels and stickers detailing dates and a few other notes. They are presumably from the A123 recall due to some cells in some modules produced in the Livonia plant having a potential misalignment issue.

Sutho's DMC EV Electric DeLorean

Posted: Thu, 19 Jul 2012, 15:02
by PlanB
So did they come with BMS Brett or you rolled your own?

Sutho's DMC EV Electric DeLorean

Posted: Thu, 19 Jul 2012, 17:26
by Sutho
They come with their own BMS which didn't seem to work.

I used Tritium's BMS. The BMS nodes were about 40% of the size of the A123 units and fit quite well under the factory cover plate.

Photos below show Tritium BMS node in the end of a module.....and one of the Fisker date labels I mentioned in a post above.

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Sutho's DMC EV Electric DeLorean

Posted: Thu, 19 Jul 2012, 17:34
by coulomb
Sutho wrote: I needed to purchase 50% more than I required to get enough modules of the right standard.

Any plans for the rest of what you bought? Outright damaged cells are pretty useless, I guess, but those that just don't come up to standard for a high-end EV might have some uses elsewhere.

Sutho's DMC EV Electric DeLorean

Posted: Thu, 19 Jul 2012, 21:07
by Sutho
I plan to repair some to keep as spares for this vehicle.....and maybe use some of the components from the rest to build packs for another project.

Sutho's DMC EV Electric DeLorean

Posted: Fri, 20 Jul 2012, 01:08
by Sutho
Our local News done a story on our Electric Delorean tonight. For any that are interested, it can be viewed here:

NBN News - Electric Delorean - Back to the Future

Cheers,
Sutho

Sutho's DMC EV Electric DeLorean

Posted: Fri, 20 Jul 2012, 02:06
by BigMouse
Haha, nice! They had some fun with the special effects on that video.

Another question about those A123 modules: how are the cells connected internally? There's a ton of talk about the AMP20 cells and everyone seems to have their own way of connecting them. It'd be cool to see some photos of how the factory does it.

Sutho's DMC EV Electric DeLorean

Posted: Fri, 20 Jul 2012, 02:43
by PlanB
Nice app on the Android tablet about a minute into that movie, is it this?

Sutho's DMC EV Electric DeLorean

Posted: Fri, 20 Jul 2012, 18:26
by Sutho
BigMouse wrote: Haha, nice! They had some fun with the special effects on that video.

Another question about those A123 modules: how are the cells connected internally? There's a ton of talk about the AMP20 cells and everyone seems to have their own way of connecting them. It'd be cool to see some photos of how the factory does it.


A123 insert link plates over the tabs and then laser weld them which also shortens the tab considerably. This method would be near impossible to replicate without the same machinery.

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Sutho's DMC EV Electric DeLorean

Posted: Fri, 20 Jul 2012, 18:27
by Sutho
PlanB wrote: Nice app on the Android tablet about a minute into that movie, is it this?


Yes....that's the one. Works quite well too.

Sutho's DMC EV Electric DeLorean

Posted: Sun, 22 Jul 2012, 04:16
by BigMouse
Interesting. I had read they were laser welded, but had never seen how it was actually packaged. Curiosity satisfied. It's a shame A123 is so terrified of hobbyists. These modules would probably sell quite well if they offered them to end users directly.

Sutho's DMC EV Electric DeLorean

Posted: Sun, 03 Mar 2013, 01:21
by Sutho
We have upgraded the motor controller in our Electric DeLorean from the 300Arms Tritium Wavesculptor to a 450Arms Rinehart Motion Systems (RMS) PM100DXR.

Rinehart usually reserve the 450Amp DXR model for race applications only, but they agreed to us using it for this vehicle so we could unlock the full potential of the EVO Electric Axial Flux Motor.

The 450Arms allows the EVO motor to produce an incredible 612Nm of torque....and I must say, the performance is now amazing! Have only been able to test in the rain so far, but even with new tyres it breaks traction at 50km/h in 3rd gear. This is the performance we have been looking for. :-)


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The vehicle now incorporates the following major components:

- EVO Electric AFM140 Axial Flux Motor
- Rinehart Motion Systems PM100DXR Motor Controller
- A123 Systems Nanophosphate Battery Modules
- Tritium BMS
- Brusa 3.3kW Charger
- Delphi 2.2kW DC Converter


Cheers,
Sutho

Sutho's DMC EV Electric DeLorean

Posted: Sun, 03 Mar 2013, 01:50
by woody
Are you selling your wavesculptor? 300A is enough for me :-)

Sutho's DMC EV Electric DeLorean

Posted: Sun, 03 Mar 2013, 02:12
by Sutho
Yeah...I no longer need the Wavesculptor, so I guess it's for sale. A few people have expressed interest, so maybe PM me an offer?

Sutho's DMC EV Electric DeLorean

Posted: Sun, 03 Mar 2013, 03:28
by jonescg
Great to hear mate! So you can use field weakening to wick it up to full speed?

Sutho's DMC EV Electric DeLorean

Posted: Sun, 03 Mar 2013, 03:45
by Sutho
Yes....definitely getting more RPM. There are a few parameters that can be adjusted to control field weakening.

I will monitor and fine-tune some of these parameters more when it stops raining here...

Sutho's DMC EV Electric DeLorean

Posted: Sun, 03 Mar 2013, 04:13
by tsport100
Just curious how you are measuring that torque output?

Sutho's DMC EV Electric DeLorean

Posted: Sun, 03 Mar 2013, 04:29
by Sutho
Torque figure is from EVO specifications with a motor current of 450Arms. This figure is in line with RMS's calculations and experience.

The PM100DXR motor controller calculates motor torque based on motor currents and parameters of the motor. This figure can be viewed in a Watch List while driving, but I need to try that with a co-pilot as I was having trouble doing both.