The Electric Vehicle The Electric Vehicle Presented by: Keith Kolkebeck Ben McGrath Mike Rehrman Advisor: Dr. Scoles Project 4

Overview BackgroundBackground Why an EV?Why an EV? AccomplishmentsAccomplishments High & low voltage systemsHigh & low voltage systems InstrumentationInstrumentation Conversion CostConversion Cost Future workFuture work

Background 1984 Honda CRX EV1984 Honda CRX EV –Donated to Drexel University Electrical Vehicle Team –Majority of mechanical systems complete for original design –Majority of electrical systems complete, but incorrectly installed

Goals Assess and rewire high/low voltage systemsAssess and rewire high/low voltage systems Test high/low voltage systemsTest high/low voltage systems Assess original batteriesAssess original batteries Electrical instrumentation and data acquisitionElectrical instrumentation and data acquisition Road test the EVRoad test the EV

Mike Rehrman

Why an EV? Environmentally friendlyEnvironmentally friendly Ideal for cities or local useIdeal for cities or local use Low maintenanceLow maintenance $0.044 per mile ($0.07 for gas)*$0.044 per mile ($0.07 for gas)* * Formula taken from Bob Brant. Built Your Own Electric Vehicle. McGraw-Hill, Inc

Accomplishments Assessed high voltageAssessed high voltage Assessed and rewired low voltageAssessed and rewired low voltage New batteriesNew batteries DocumentationDocumentation Installed electrical instrumentationInstalled electrical instrumentation –Cruising Equipment’s E-meter –Indicator lights –Low voltage analog meters

High Voltage System Located a good reference diagram*Located a good reference diagram* Verified the installed wiringVerified the installed wiring Produced high voltage diagram of Drexel’s EVProduced high voltage diagram of Drexel’s EV Batteries on order, not receivedBatteries on order, not received * Page 93 of Michael P. Brown’s Convert It. Future Books

Components Volt Trojan 27TMH batteries10 12-Volt Trojan 27TMH batteries 9” Advanced D.C. Motor9” Advanced D.C. Motor Curtis PMC potboxCurtis PMC potbox Curtis PMC motor controllerCurtis PMC motor controller 200A Breaker200A Breaker K&W Engineering BC-20 battery charger with LB-20 line boosterK&W Engineering BC-20 battery charger with LB-20 line booster Albright ContactorAlbright Contactor

10 12-Volt Trojan 27TMH Batteries 9” D.C. Motor Curtis PMC Controller 200A Breaker Overheat Light Charging Light Charger & Booster

Charging Minimum charger requirements:Minimum charger requirements: –120-volt AC source –20 Amps Approximate full charge time of 8 hoursApproximate full charge time of 8 hours Interlock relayInterlock relay

Batteries Trojan 27TMH deep discharge batteriesTrojan 27TMH deep discharge batteries Weight 55 lbs eachWeight 55 lbs each Need to be replaced every 3-4 yearsNeed to be replaced every 3-4 years

Keith Kolkebeck

Low Voltage System Determined wired improperlyDetermined wired improperly Completely rewired low voltage systemCompletely rewired low voltage system Integrated the OEM low voltage system (lights, horn, etc…)Integrated the OEM low voltage system (lights, horn, etc…) Tested systemTested system

Components Sevcon DC-to-DC converterSevcon DC-to-DC converter 12-Volt auxiliary battery12-Volt auxiliary battery Ignition switchIgnition switch OEM 12-volt electrical systemOEM 12-volt electrical system Key relayKey relay Potbox relayPotbox relay Interlock relayInterlock relay Indicator lightsIndicator lights Analog voltmeter and ammeterAnalog voltmeter and ammeter Vacuum pump with switchVacuum pump with switch

Safety Key Switch RelayKey Switch Relay –Allows 120V input to the DC-DC converter Potbox RelayPotbox Relay –Turns on Controller when accelerator pressed Interlock RelayInterlock Relay –Prevents operation during charging

Sevcon DC-DC Converter 12V Aux. Battery Key Switch OEM 12V System Key Relay Potbox Relay Voltmeter Ammeter Potbox Key On Running Light Tripped Pressed

Ben McGrath

E-Meter MonitorsMonitors –voltage –current –amp-hours consumed –time remaining ProgrammingProgramming

E-meter Setup Shunt Serial Port Prescaler 500V Power High Voltage Current

Serial Communication RS-232 data linkRS-232 data link –Computer –Palm Pilot * –Palm Pilot  * Output data fileOutput data file Analysis dataAnalysis data –Matlab –Excel *Application written by Peter Ohler

Conversion Cost

Future Work Comprehensive road testComprehensive road test Data collection and analysis for various driving conditionsData collection and analysis for various driving conditions Installation of heater core with temperature controlsInstallation of heater core with temperature controls

Special Thanks Dr. Scoles - AdvisorDr. Scoles - Advisor Peter Ohler – Palm Pilot E-meter applicationPeter Ohler – Palm Pilot E-meter application Jim Le/Dan Lump – Trojan BatteryJim Le/Dan Lump – Trojan Battery

Pictures

Questions