Friday, March 1, 2013

Start of the EV conversion

Since some years I´ve been planning to convert a Reliant Robin 850 to electric power. This is my blog about the conversion that I start tomorrow. In my mind is the Robin a perfect platform because its very light (400 kg incl. ICE) , a very simple set-up without complex Airco, power steering or even a radio and a separate chassis/body for easy access when the body is removed. 
I bought my Reliant 1.5 years ago and drove it quite often and semi rebuilt the engine because it blew up on me... But it's still a very lovable car, I know it pretty good by now and only more reason to make it a EV!

For my conversion I'm going for a DC setup with a clutch less coupling to the electric motor. I want to build it on a budget so I want to keep it as simple as possible. Here a scheme of what I have planed:

As you can see in the scheme the current plan is to use 6 battery's (accus) of each 12v for a total of 72v with one 12v battery for the auxiliary power. This runs trough a Alltrax AXE 7245 controller that breaks up the full power in to as much as the throttle tells it to. This controlled power goes to a D&D ES 15-6 motor which turns it into motion that goes via a coupler and adapter plat to the transmission and eventually the wheels. I'll some safety features, charger, link to 12v cables a fuel gauge and I should have a working EV.

I’m hoping on a top speed of around 80 km/h and a range between 50 and 100 km depending on the battery’s that I install. With 12v deep cycle battery’s as the cheap, easy, heavy and low range option and lifepo4 battery’s as the best option. For now I’m sticking with the cheap and easy option for the first try always leaving the door open for an upgrade.

The motor/controller combination on 72v has a less horsepower than the internal combustion engine (ICE) but more torque. Both horsepower and torque are peaked at low RPM with the electric set-up instead of relative high rpm. So it should be good from 0 km/h.
39 at 5500 rpm
25 at 1600 rpm
Torque ft/ib
46 at 3500 rpm
65 at 1600 rpm

I'm not so good at all the electronic calculations so I'll see what happens when everything is in. It's all theory now.

First things first, the car has to come to the garage before anything can be done. Then I'll check if the plans are feasible and if the first parts are ordered there is no turning back!

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