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Introduction to Electric VehiclesEd RistadAlternative Fuel Vehicle InstructorSanta Rosa Junior Collegealtfuels@sonic.netSolar Living Institute EV101January 31, 2009 9 AM - 5 PMGreen Building Exchange, South San FranciscoThis presentation is dated 1/28/09 and posted atwww.nbeaa.org/osev/presentations/ev intro.pdf.

Introduction to EVsWhat do You Want in an EV?What are Your EV Choices?The Economics of EVsThe EV Conversion ProcessEV Resources

Introduction to EVsWhy EVs?Types of EVsEV HistoryEV Charging

Why EVs?All of these issues showed up in the paper one morning.

Why EVs?Energy Independence60% of 2006 US oil consumption was imported per the US Government EnergyInformation Administration Basic Petroleum l.html.Greenhouse Gas ReductionTransportation accounted for 42% of greenhouse gas emissions in Sonoma County in2000, according to the Climate Protection Campaign’s January 2005 report“Greenhouse Gas Emission Inventory for all sectors of Sonoma County, ws/documents/AP INVEN.PDF.Air and Water Pollution ReductionAsthma cost 12.7B in 1998 and can be caused by vehicle exhaust, per the Center forDisease Control “Asthma Speaker’s Kit”, www.cdc.gov/asthma/speakit/default.htm.See www.nbeaa.org/bev faq.htm for more frequently asked EV questions.

Why EVs?EV Energy 1234Efficiency:Petrol ICEEVs charged byICE gridEVs offset by PVsmade by ICE gridEVs offset by PVsmade by PV gridCombustion15%35%35%n/aGridn/a90%90%90%Energy n/a90%90%90%AC Drive Systemn/a85%85%85%TOTAL15%21%63%Infinite for 5.5B yearsEfficiency of fuel input to motor shaft output only. Energy to make EV can be higher, but it makes up a small amount ofthe total energy consumed from cradle to grave of an ICE.

Types of EVsHybridFord Escape HEVBattery OnlyTesla Roadster BEVPlug-in HybridToyota Prius PHEV conversionFuel CellHonda FCX hydrogen FCV

EV History:Examples of low speed past production EVs1914 Detroit Electric: 80 mile range,20 MPH, NiFe batteries1974 Zagato Elcar: 35 MPH, 35 milerange, PbA batteries1980 Commuter Vehicles CommutaCar:30 MPH, 40 mile range, PbA batteries

EV History:Examples of high speed past production EVs that weresold that can still be found for sale used1997 Chevrolet S10 EV: 95 milerange, NiMH batteries1998 Ford Ranger EV: 82 milerange, NiMH batteries1998 Solectria Force: 84 mile range,NiMH batteries2002 Toyota RAV4 EV: 94 milerange, NiMH batteries

EV History:Examples of high speed past production EVs that wereleased only and can not be found used1999 Chrysler EPIC: 79 mile range,NiMH batteries1999 General Motors EV1: 140 milerange, NiMH batteries1999 Honda EV Plus: 80 mile range, 2000 Th!nk City: 55 MPH, 45 milerange, NiCd batteriesNiMH batteries

EV History:Range Record HoldersAC Propulsion tZero: drove 302 mileson a single charge at 60 MPH in 2003,Lithium Ion batteriesPhoenix Motorcars SUT: charged 50times in 10 minutes with nodegradation in 2007; 130 mile rangeSolectria Sunrise: drove 375 miles on asingle charge in 1996, NiMH batteriesDIT Nuna: drove 1877 miles averaging 55.97MPH on solar power in 2007, LiPo batteries

EV History:Speed Record Holderslink to videolink to videoMotorcycle: Killa-Cycle, 7.890 secondsDragster: Current Eliminator V, 7.956and 167.99 MPH quarter mile in 2008 with seconds and 159.85 MPH quarter mile inA123 Systems nano-LiFePO4 batteries2007 with Altairnano Li4Ti5O12 batterieslink to videolink to videoModified Conversion: Smoke Screen S10, Pro Street Conversion: White Zombie,11.083 seconds and 119.91 MPH quarter 11.466 seconds and 114.08 MPH quartermile in 2008 with AGM batteriesmile in 2007 with A123 Systems nanoLiFePO4 batteries

EV ChargingAt homeAt a public on-grid PVcharging station in VacavilleAt an RV parkFrom an off-grid PVgenerator trailer

Introduction to EVs What do You Want in an EV?What are Your EV Choices?The Economics of EVsThe EV Conversion ProcessEV Resources

What do You Want in an EV?Students to brainstorm key features:

What do You Want in an EV?Students to brainstorm key features:Payload

What do You Want in an EV?Students to brainstorm key features:Range

What do You Want in an EV?Students to brainstorm key features:Speed

What do You Want in an EV?Students to brainstorm key features:Charge Time

Introduction to EVsWhat do You Want in an EV? What are Your EV Choices?The Economics of EVsThe EV Conversion ProcessEV Resources

What are Your EV Choices?Buy2, 3 or 4 wheellimited or full speedMakeConversion OverviewDonor VehicleBatteriesDrive SystemCharging SystemExamplesWaitEV Research

Buy:Examples of Current Production 4 Wheel EVswww.acpropulsion.comAC Propulsion eBox conversion: 120 milerange, LiIon batteries; 55K plus Scion xBwww.commutercars.comCommuter Cars Tango T600: 200 milerange, LiIon batteries; 109Kwww.teslamotors.comTesla Motors Roadster: 220 milerange, LiIon batteries; 109Kwww.venturifetish.frVenturi Fetish:155 mile range, LiIonbatteries; 400K

Current Production 3 and 2 Wheel EVswww.zapworld.comZap Xebra conversion: 40 MPH, 25 milerange with AGM PbA batteries; 12Kwww.vectrix.comVectrix Motorcycle: 62 MPH, 60miles with NiMH batteries, 12Kwww.myersmotors.comMyers Motors NmG: 45 mile rangewith LiIon batteries; 30Kwww.thunderstruck-ev.com/Lepton.htmLepton Scooter: 28 MPH, 30 mileswith AGM PbA batteries, 2K

Make:Conversion Overview

Make:Conversion OverviewComponents found on radiator plateBrusa NLG511

Make:Conversion OverviewMajor EV components not in radiator boxAzure Dynamics AC24LS(DMOC445 Controller not shown)motorElectro Automotive Custommotor to clutch and transmission adapterValence Technologies U24-12XPbatteriesconsole

Make:Donor VehiclePayload after ICEremoved vs.weightSpace to put EVcomponentsCost ofconversioncomponentsScooter Motorcycle Mini car Compact car Compact truck Mid-size car -Mid size truck -Full size car- -Full size truck- -Class

Make:Donor Vehicle

Make:BatteriesTypePower Energy StabilityMaxtempLifeToxicityCostLiFePO4 -LiCO2 --- -NiZn - NiCd- - PbA AGM - -- PbA gel - -- PbA flooded -- -- Available large format only considered; NiMH, small formatlithium and large format nano lithium not included.

Make:BatteriesTypeMakesModelsLiFePO4Thunder SkyValence TechnologiesLMPU-Charge XPLiCO2KokamSLPBNiZnSBSEvercelNiCdSaftSTMPbA AGMBB BatteryConcordeEnerSys HawkerEVPLifelineGenesisOdysseyOrbital Extreme Cycle DutyYellow TopBlue TopExideOptimaPbA gelEast Penn DekaDominatorPbA floodedTrojanUS BatteryGolf & Utility VehicleBB SeriesExamples of commonly used EV batteries.Search EV Discussion List Photo Album at www.evalbum.com for details.

Make:BatteriesCalculating Voltage DropVoltage sags with increased current and internal resistanceper Ohm’s Law, robbing potential output power to generate heat.voltage current x resistanceVVolts Ix Amps xROhms1000 milli-Ohms 1 OhmExample voltage drop on 12 Valence U24-12XPs at continuous current rating:12 x 150 Amps x .006 Ohms 10.8V on 154V nominal pack -7%

Make:BatteriesCalculating Battery PowerAcceleration rate varies with peak power.Top speed and hill climbing ability varies with continuous power.power current x voltageP IxVWatts Amps x Volts1000 watts 1 kilo-Watt 1 kW1 kW 1.34 HorsepowerExample battery power of 12 Valence U24-12XPs at continuous current rating:12 x 150 Amps x (12.8 Volts - .006 Ohms x 150 Amps) 21.4 kW

Make:BatteriesCalculating EnergyBattery capacity is how much energy it will hold.CapacityWhWatt-hours power x time WxhWatts x hours1 Watt-hour is equivalent to 1 Watt drawn for 1 hour1000 Wh 1 kWh1 kWh 3413 BTUsExample capacity of 12 Valence U24-12XPs at continuous current rating:12 x 100 Amp-hours x (12.8 Volts - .006 Ohms x 150 Amps) 14.2 kWh

Make:BatteriesEstimating RangeRange varies directly with battery capacity.Range varies inversely with DC energy consumption rate.Range capacity / DC consumption rate Watt-hours / Watt-hours per mileExample range estimate of Mustang EV:14,200 Wh / 375 Wh / mi 37.9 miles with new batteries37.9 miles x 0.8 30.2 miles after 5 years, assuming 4% decline per yearSee http://www.geocities.com/chris b jones@prodigy.net/EV/1.htm for details.

Make:BatteriesEV Battery ComparisonSpecific Power vs. Energy900800LiCoO2Specific Power, GMNiZnNiNaCl200gel100NiCd00255075Specific Energy, Wh/kg100125150

Make:Drive SystemControllerPowerAC: regen,efficient,brushlessSolectria MES-DEA -Siemens -ACPropulsion -Curtis -- SafetyAvailableCost

Make:Drive SystemCalculating Motor PowerMotor Power varies with power input and drive system efficiency.output power input power x efficiencyPo PixEffWatts Watts x efficiency ratioExample peak motor shaft power of Mustang EV :325 Amps x 12 x (12.8 Volts - .006 Ohms x 325 Amps) x 75% 31.7 kW 42.5 HorsepowerNote: this propels a 3000 pound car 0-60 MPH in 23 seconds, approximatelyat the flow of traffic – much less than the peak rating of gasoline cars.

Make:Drive System Comparison1966 Mustang Motor Options400Brusa ASM 8-24-10350289 4V Hi PoShelby GT350289 4V Std300289 2VMES-DEA 200-330Peak Torque250Azure AC55gasolineACDC200200 1VBrusa ASM 6.17.12150AC PropulsionNetgain Warp11MES-DEA200-150100Advanced DC 9"Advanced DC 8"50Azure AC24, 24LSNetgain Warp90050100150200250300350Peak HorsepowerNote: EV motors have wider RPM torque band so they better compare toICE motors with 25% more torque and horsepower.

Make:Charging orCorrectionBrusa -DeltaQ- -Zivan --- ManzanitaMicro - -- Russco -- -- SealedUL,FCCcost

Make:Charging SystemEstimating Charge TimeCharge time varies with charger output power.charge time battery capacity / charger powert Wh/Whours Watt-hours / WattsExample charge time of Mustang EV :12 x 12.8 Volts x 100 Ah / 3300 W 4.7 hours

Make:ExamplesJohn Warobiew’s 1983 VolkswagenRabbit GTI, 35 mile range, PbAbatteriesPeter Oliver’s 1956 Porsche 356 Speedsterreplica, 100 mile range, LiFePO4 batteriesChris Jones’ 1966 Ford MustangConvertible, 33 mile range, LiFePO4batteriesEd Ristad’s 1990 VolkswagenCabriolet, in process

Wait:EV ResearchStanford University Silicon Nanowireelectrodes: 3X capacity improvementexpected for Lithium batteriesMIT Nanotube ultracapacitors: veryhigh power, 1M cycle energystorage approaching Lithium batterycapacity

What do You Want to Do?Students to brainstorm their thoughts abouttheir own EV plans, including:MakeBuyWait

Introduction to EVsWhat do You Want in an EV?What are Your EV Choices? The Economics of EVsThe EV Conversion ProcessEV Resources

The Economics of EVs:Worst Case Example2008 MustangConvertible ICE1966 Mustang Valence LiFePO4EV ConversionDurable hardwarecost, excludingbatteries 24K new Kelley BlueBook value 13K conversion components 5K conversion labor 10K donor car 28K subtotal: 4K moreBatteryamortizationn/a 17K every 5 yearsFinanced at 5% APR 12 per dayFuel efficiency20 MPG2 miles per kWhFuel cost 2 per gallon12 cents per kWhFuel cost per mile10 cents6 centsDaily ongoing cost 2at 20 miles per day 13.25: 11.25 more per dayAssumes maintenance cost is low for both vehicles.

The Economics of EVs:Ways to break even Gas price rises 6.5X to 13 per gallonGas is now 10 per gallon in England Battery price reduced 85% to 2.6KPbA achieves this, but significantly reducesavailable payload for passengers and cargo, istoxic, and requires hydrogen gas management;Loose LiFePO4 cells are cheaper, but reliabilityand BMSs just being proven; volumediscounts could help Battery life extended 6.5X to 33 years Government Incentives for EVs were 4K per yearOr some combination of the above.

Introduction to EVsWhat do You Want in an EV?What are Your EV Choices?The Economics of EVs The EV Conversion ProcessEV Resources

The EV Conversion ProcessPreparationFabrication and tion in to VehicleTest

Preparation:Refurbish non-ICE systems including brakes, steering,suspension, electrical, interior and exterior, then measureride height

Preparation:Make transmission locating fixture

Preparation:Pull transmission and measure depth from flywheelto block, then pull motor, radiator, exhaust systemand gas tank

Fabrication and Assembly:Have custom motor adapter ring, plate and hub with pilotbushing made, then assemble ring and plate to motor

Fabrication and Assembly:Install taper lock bushing