First drive of industrial ac hilux

Post up a thread for your EV. Progress pics, description and assorted alliteration
a4x4kiwi
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Post by a4x4kiwi » Thu, 26 Feb 2009, 14:51

After a trip to the local weighbridge, I now have the EV Grin! 
... and in the excitement I forgot to take a photo or video. arrgh!

The total weight is as expected.

Front: 628kg - 41%
Rear: 916kg - 59%
===========
Total 1544kg.

The original dry curb weight was 1265. 58%F 42%R
279kg heavier

First run efficiency is 2.4kwh / 7.2km = 333kwh/km.
The silly thing with the Danfoss is that I think that the 2.4kwh includes driving and regen.

Points to note:
This is not counting regeneration.
I was driving quite aggressively, but not fast. Max speed was about 60kph.
I live at the top of a 100m hill.
The motor and controller were only warm to touch, even after a 100m climb in less than 1km.
Regen was set at 20% (3kw)/. I should be able to increase this to 66% (10kw) to have the diesel braking effect.

I have the tachometer reading kW but unfortunately it peaks at the motor maximum (15kw) so is not very useful. I will switch tacho back to RPM.



Last edited by a4x4kiwi on Thu, 26 Feb 2009, 04:16, edited 1 time in total.
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Post by Electrocycle » Thu, 26 Feb 2009, 15:41

good stuff!
I'll have to come and have a look some time :)
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Richo
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Post by Richo » Thu, 26 Feb 2009, 17:31

good work Image
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Post by acmotor » Thu, 26 Feb 2009, 17:34

Great work !

True, the Danfoss counts regen as part of total kW (it is thinking of motor thermal ). I look at the torque direction in data file and also my add on battery current measurement to establish regen component.

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Post by Johny » Thu, 26 Feb 2009, 17:43

Great news Mal.

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Post by lachlanmac » Fri, 27 Feb 2009, 04:33

It is so exciting to make that first drive. Heart in mouth, giant grin and the desire to shout loudly "I did it"

Well done

Lach

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Post by Dean » Sat, 28 Feb 2009, 00:35

Ive been "lurkin" on here for quite a while, and ive followed your posts. Great work your inspiring me and other lurker's im sure.

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Post by antiscab » Sat, 28 Feb 2009, 07:29

Welcome Dean.
feel free to lurk, its the first step towards obsession :D

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Post by woody » Mon, 02 Mar 2009, 20:46

regarding the pickup being too slow/course, can you insert a micro inline which multiplies the pulses.

Nothing fancy
e.g.
the last two "real pulses" were X ms apart
send 10 pulses X/10 ms apart.

If you don't get the next pulse, don't send any more pulses.
If you do get it (early), just start again (discarding any unsent pulses).

cheers,
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Post by HeadsUp » Tue, 03 Mar 2009, 07:05

hi Mal , great work mate

got a question regarding the motor mounting bracket , it looks like about 5 mm sheet ?

i think mine will be around 8 mm bisalloy , which is a higher strength steel than mild steel

bisalloy is 800 Mpa , mild steel is 400 Mpa , so i can use thinner steel and save weight .

i will probably get an engineer to check the maths before i build it though , these things can put out very high torque, and the electric motor mounts are closer together than the original motor , so they really need more strength around the motor mounts

cheers , and enjoy the driving . looking forward to it myself

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Post by a4x4kiwi » Tue, 03 Mar 2009, 22:03

WAHOO. Just past engineering signatory inspection.

He was dissapointed he couldnt make any suggestions or reccomendations : Image
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Post by woody » Tue, 03 Mar 2009, 22:41

Congrats, great work!

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Post by a4x4kiwi » Wed, 04 Mar 2009, 00:09

@woddy. Thanks. Not far to go now.

@HeadsUp the motor mount is flat steel plate. 5.2mm think (from memory), let me know if you need exact details.

Now that it has passed muster. I can mention that it is bolted straight to the chassis as there is minimal vibration and as it is an induction motor, no shock loading. :)


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Post by a4x4kiwi » Sat, 07 Mar 2009, 20:11

Today I am road legal!
Image
I can see I still have some controller tweaking to do, but I am done!


Image
Last edited by a4x4kiwi on Sat, 07 Mar 2009, 09:21, edited 1 time in total.
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Post by Johny » Sat, 07 Mar 2009, 22:15

Great to hear Mal!

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Post by HeadsUp » Sat, 07 Mar 2009, 23:56

good onya Mal

i am guessing thats a heck of a lot of hours of work

400 plus hours ?

EDITED....... maybe a tad more than 400 hours then   Image

anyway mate ....... while youre out driving , could you pick up the newspaper for me and drop it in to my place on your way ?   Image

enjoy !
Last edited by HeadsUp on Sun, 08 Mar 2009, 07:20, edited 1 time in total.

a4x4kiwi
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Post by a4x4kiwi » Sun, 08 Mar 2009, 15:54

Silicon is just sand with attitude.

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Post by Rattrap » Sun, 08 Mar 2009, 16:22

Well done mal, congrats!

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Post by acmotor » Sun, 08 Mar 2009, 19:50

Hey Mal, I like the 'torqo meter' I want one.
What scale have you used, Nm x 100 ?

Note with the multicharger system, take note of the startup DC bus voltage after recharge. I drove off with one battery module not recharged as there had been a blow fuse ( my doing Image ) in a charger. Fortunately I was looking at voltages at the time and was so alerted to the problem.
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Post by Electrocycle » Mon, 09 Mar 2009, 02:25

what's the range like?

You can come and visit and charge up for the home trip if you like :P
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Post by EV2Go » Mon, 09 Mar 2009, 19:51

Congrats Mal, great to hear your mobile (unlike me who became unmobile over the weekend Image)

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Post by a4x4kiwi » Tue, 10 Mar 2009, 04:33

Here are some observations after a longer drive today:

First of all. What fun!

Now for some stats.

24.6km Very hilly terrain
Start voltage was 657v. 100%SoC according to the greensaver battery data sheet.
End voltage was 621v. 50%SoC.
Energy used (if you consider voltage an accurate means of measuring SoC) = 6kwh. Efficiency = 250Wh/km

I am mixing measurement units here however, the kwh counter read 8.2kwh. This is motor energy both driven and regen. This gives 2.2kWh regen which I find very hard to believe, considering the charge efficiency will not be great.

For now I will rely on the pack voltage for SoC while stationary. I have printed out a lookup table to translate voltage into SoC.

I had the regen set for 10kW (66.6%). This gave over voltage warnings (801+ volts) and was a bit much for the batteries at 16v per cell, but did not trip on a full charge. This equates to a charge current of 12.5A. minus about .5A through the balance circuit.

I have backed this off to 8kW (53.3%) to try and minimise over voltage on the batteries.

Motor heat:
As I live in a very hilly area, the motor is heating up a lot when stationary. I will use Tuarns example and add a 12v cooling fan to the motor.

I am looking at a 10" radiator fan adapted to replace the existing mechanical fan.

I will use a 'clickson' switch to allow the fan to continue running when the vehicle is off.
Last edited by a4x4kiwi on Mon, 09 Mar 2009, 17:36, edited 1 time in total.
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Post by antiscab » Tue, 10 Mar 2009, 04:40

EV2Go wrote: Congrats Mal, great to hear your mobile (unlike me who became unmobile over the weekend Image)


this seems like a recurring theme....

both my EV bike and ICE car died last weekend aswell.
coincidence? :(

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

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Post by acmotor » Tue, 10 Mar 2009, 07:41

Mal,
What was the kW to recharge the pack ? Oops, tomorrow for the data ?

If you were in hilly terrain, then regen will be considerable. 30% is not unrealistic. Regen kW that is, not all accepted as recoverable charge by battery pack unfortunately ! The ultra caps you ordered will fix that.

If the emotor is heating up, it is probably still losing sync at times.

Did the inspector drive the electrolux ? or did you hog it all ? Image

Any more video ?

Matt, do you need to start an ashes to ashes thread ? Image
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antiscab
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Post by antiscab » Tue, 10 Mar 2009, 07:53

im right now, my new contorller is on its way Image

uve just hit 1000 posts btw [:0]

Matt
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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

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