ELMOFO Electric Radical SR8

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Sutho
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Post by Sutho » Wed, 20 Feb 2013, 00:12

Hi All,

Solar Power Australia's electric vehicle division are building a high performance Electric Radical race vehicle.

The drive system will provide suitable levels of acceleration and speed to enable the vehicle to compete with it's petrol powered brethren.

The vehicle will be fast charged from solar sources to provide true zero emission racing.

The drive system incorporates:

- AMR Prototype Dual-Inline Stack AC Motors
- RMS PM150 Motor Controllers
- ELMOFO Liquid Cooled Battery Modules

More information will be provide as the build progresses.

Cheers,
Sutho

Image

Image

Image
Last edited by Sutho on Tue, 17 Sep 2013, 13:37, edited 1 time in total.

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Post by BigMouse » Wed, 20 Feb 2013, 01:38

That's pretty awesome. Love seeing a solar business involved in the EV world.

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Post by Al-Bunzel » Wed, 20 Feb 2013, 02:41

Have you seen the Radical Electric Car built by some university students in England? Then they drove it from Alaska to the southern tip of South America along the Pan American highway.

Here are some links that could be of interest to you:
http://www.racinggreenendurance.com/
http://www.radicalsportscars.com/uk/rea ... =1&r=9&t=5

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Post by Sutho » Wed, 20 Feb 2013, 02:47

Al-Bunzel wrote: Have you seen the Radical Electric Car built by some university students in England?


Yes. Very good effort. More designed for distance than outright performance.

TMG - Toyota Motorsport Germany (or in fact their partners) have built some rocketship electric Radicals that are well worth looking at. Hold current Electric Lap records at the Nurburgring.

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Post by jonescg » Wed, 20 Feb 2013, 05:44

Looks like an awesome idea! I thought electric bike racing was expensive... four wheels is eight times the price!

Oh, and I'll definitely buy my inverter from you when the time comes. I'll get the one with the fully integrated AIM dashboard too - makes high voltage battery monitoring a lot easier.
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Post by Sutho » Thu, 21 Feb 2013, 18:22

jonescg wrote:Oh, and I'll definitely buy my inverter from you when the time comes. I'll get the one with the fully integrated AIM dashboard too - makes high voltage battery monitoring a lot easier.


You'll be please to know that there has been some price improvements on the RMS inverters too. :-)

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Post by PlanB » Sat, 23 Feb 2013, 18:10

Sutho wrote: Yes. Very good effort. More designed for distance than outright performance.


I could take a bit of that, say 300km range @ a modest 100kw would do me nicely Brett.

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Post by Adverse Effects » Sat, 23 Feb 2013, 18:53

EV Porn

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Post by Sutho » Mon, 25 Mar 2013, 21:53

Some photos of our new ELMOFO liquid cooled lithium battery modules designed and built specifically for our electric race vehicle:

Image

Image

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Post by jonescg » Tue, 26 Mar 2013, 05:19

Sweet jesus...
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Post by Sutho » Fri, 17 May 2013, 05:06

Progress...

Image


Image

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Post by EV2Go » Fri, 17 May 2013, 15:06

Sutho wrote: The vehicle will be fast charged from solar sources to provide true zero emission racing.
Impressed by the technology, but exactly how do you plan to fast charge from solar? Unless you know about some cataclysmic explosion from the sun that we don't know about, how do you plan to achieve this?

You take your car to the track fully charged from solar power ok I get that, but after the first race you need to recharge... How are you going to get the huge amount of solar panels to the track to recharge? on a diesel powered truck?

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Post by Adverse Effects » Fri, 17 May 2013, 19:48

can i just have a few min alowen with this porn pls

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Post by Sutho » Fri, 17 May 2013, 20:10

EV2Go wrote:
Sutho wrote: The vehicle will be fast charged from solar sources to provide true zero emission racing.
Impressed by the technology, but exactly how do you plan to fast charge from solar? Unless you know about some cataclysmic explosion from the sun that we don't know about, how do you plan to achieve this?

You take your car to the track fully charged from solar power ok I get that, but after the first race you need to recharge... How are you going to get the huge amount of solar panels to the track to recharge? on a diesel powered truck?



The "diesel" transport truck is being fitted with a 3kW+ solar array which will charge a storage battery bank that is large enough to store enough energy for about 2 recharges. The car will be charged in about an hour via a high power DC to DC charger. The energy in the storage bank will be replenished by the sun over the next week.

In the future the transport truck will also be electric.

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Post by Johny » Fri, 17 May 2013, 20:44

It must be nice to have such an unlimited budget.
Who is sponsoring this build?

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Post by Sutho » Fri, 17 May 2013, 22:12

Johny wrote: It must be nice to have such an unlimited budget.
Who is sponsoring this build?


It would be nice to have an unlimited budget, but that is not the case. In lieu of talking about how it should or could be done, I am putting my (company's) money where my mouth is and doing it.
Last edited by Sutho on Fri, 17 May 2013, 12:32, edited 1 time in total.

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Post by Stiive » Fri, 17 May 2013, 22:53

Those battery enclosures look very expensive. The side plates look machined, but what about the top orange bits?
Is the system water cooled/heated or something? Why the need for such precision?

I guess if your gonna spend tens of thousands on batteries, might as well spend thousands protecting them.

Damn i wish i could come see this beauty in person - when u next in Melb?
Rgds,
Stiive

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Post by Sutho » Fri, 17 May 2013, 23:27

Stiive wrote: Those battery enclosures look very expensive. The side plates look machined, but what about the top orange bits?
Is the system water cooled/heated or something? Why the need for such precision?

I guess if your gonna spend tens of thousands on batteries, might as well spend thousands protecting them.

Damn i wish i could come see this beauty in person - when u next in Melb?


The whole case is CNC machined billet aluminum. They are not cast and not welded. I couldn't buy battery modules (of an acceptable weight) capable of continuously delivering the required current without overheating, so I teamed up with an ex-Cosworth engineer and designed and built some that could.

When the vehicle is running, I will explain more about how these modules work and you will understand why they have such precisely engineered cases.

I appreciate your enthusiasm. You are welcome to drop in to our workshop in Newcastle and see the car.

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Post by Stiive » Fri, 17 May 2013, 23:46

Sutho wrote:
The whole case is CNC machined billet aluminum. They are not cast and not welded. I couldn't buy battery modules (of an acceptable weight) capable of continuously delivering the required current without overheating, so I teamed up with an ex-Cosworth engineer and designed and built some that could.


Sounds expensive. Atleast they look wicked!! :)
We've never found the pouch cells to heat up that much even at 10C+. The tabs are the most likely to heat, but are fine as long as the connection has enough surface area and is well clamped. We sat on the dyno at full power with the IR guns on the battery packs with no significant heating so it always interests me to hear others having issues.
What sort of temps were you seeing? What C rating? What batteries?
We are using Kokams
Sutho wrote: When the vehicle is running, I will explain more about how these modules work and you will understand why they have such precisely engineered cases.


Very interested to hear
Sutho wrote:I appreciate your enthusiasm. You are welcome to drop in to our workshop in Newcastle and see the car.


Damn, I was just in Newcastle last week for the Transport Innovation Workshop. Were you also there? Unfortunately I didn't get to meet everyone.

Rgds,
Stiive

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Post by Sutho » Sat, 18 May 2013, 04:55

Stiive wrote:Sounds expensive. Atleast they look wicked!! :)
We've never found the pouch cells to heat up that much even at 10C+. The tabs are the most likely to heat, but are fine as long as the connection has enough surface area and is well clamped. We sat on the dyno at full power with the IR guns on the battery packs with no significant heating so it always interests me to hear others having issues.
What sort of temps were you seeing? What C rating? What batteries?
We are using Kokams
We are also using Kokam. Will be running peaks of 12C, a relatively high average and will be using a lot of regen.

What vehicle set-up were you running on the dyno.....and how long were you pulling 10C?
Stiive wrote:Damn, I was just in Newcastle last week for the Transport Innovation Workshop. Were you also there? Unfortunately I didn't get to meet everyone.


Unfortunately I missed the Transport Innovation Workshop due to other commitments.

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Post by Sutho » Thu, 13 Jun 2013, 04:57

Our electric Radical is up and running.

Video of drive system running: http://www.youtube.com/watch?v=z9bPY-xXFCQ

Small test drive in our car park: http://www.youtube.com/watch?v=GxRC7gSA ... e=youtu.be

Time to get the bodywork back on, get it on the dyno and then get it on the track.

Cheers,
Sutho

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Post by Stiive » Thu, 13 Jun 2013, 15:17

Firstly, congrats! Looks awesome, and fast.



Sutho wrote: We are also using Kokam. Will be running peaks of 12C, a relatively high average and will be using a lot of regen.

What vehicle set-up were you running on the dyno.....and how long were you pulling 10C?


Induction motor was in the car (open wheel racer). Rear wheel chain drive through a spool.
Going back over my videos, we actually weren't pulling 10C constantly on the dyno - more like 7C. With short bursts in the dyno power run of 14C. From a cold start, monitoring throughout testing, the temperature of the batteries never increase over a few degC which I thought was promising.

This was in 2011, don't think anyone has done much more dyno testing on the vehicle(s) since. The endurance race is about 20mins - last year it was a 40deg day - the motor overheated, but again the batteries seemed to be fine. We have individual temp monitoring of each cell through the BMS - I know they have never gone out of spec and caused a fault, but i've never looked at the log file.
What BMS are you using?

I know a lot of the European teams don't run any battery cooling, but I guess over there the probability of 40deg+ race conditions is low.

Still, better to have too much temperature conditioning, than not enough on the time you need it. Your boxes look great.

Sutho wrote:- AMR Prototype Dual-Inline Stack AC Motors


Can you provide more details on these motors? What is AMR?

Great project. I see your using dual 800A fuses - bit overkill? Whats the pack voltage? Do you really expect to put that kind of power to the road?

Rgds,
Stiive

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Post by Sutho » Fri, 05 Jul 2013, 04:58

Quick video of our ELMOFO Electric Radical at Eastern Creek today:

http://www.facebook.com/photo.php?v=565 ... =2&theater

Cheers,
Sutho

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Post by BigMouse » Fri, 05 Jul 2013, 16:02

Looks (and sounds) great! It's a shame I missed it yesterday. I'll have to make another trip up there sometime and check out Varley at the same time. I didn't even realize they were up that way too. Nothing EV ever happens here in Wollongong ;-)

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Post by Sutho » Fri, 05 Jul 2013, 16:46

BigMouse wrote: Looks (and sounds) great! It's a shame I missed it yesterday. I'll have to make another trip up there sometime and check out Varley at the same time. I didn't even realize they were up that way too. Nothing EV ever happens here in Wollongong ;-)


Yes...the video doesn't do it full justice. Still have a bit of fine tuning to do, but I am really happy with the result.

Sorry I missed you yesterday. The track organisers cut our track time short, so we had to wait a few hours to get back on to do our last test run.

The car will be doing some demonstration laps at the Shannon's National Event at Eastern Creek in a week and a half. Will be driven by a high profile race driver, so should get some very good attention for Electric Vehicles. It has already converted a few of the racing skeptics in it's brief outing yesterday. :-)

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