Design
Project design
Research
Some related projects from the internet: Reference designs
Modeling: EV calc model
2008 Original goal
My daily commute is 8 miles one way, reaching a max speed of 55mph (usually only for 3 miles and only in the morning going to work – never in the evening – ATL traffic!)
Minimum system performance is a range of = 16 miles (round trip to work) reaching a top speed of 55mph for about 30-40% of time. Daily recharge option.
Ideally would like to be able to make a round trip to the airport. ATL international is 40 miles door to door from my house, most of the way is freeway at 55-65mph. The ideal would be able to make the trip there and back (80 mile round trip), but an option could be talk to some of the off site parking lot folks and see if a recharge option could be found. Would definitely be good promotional opportunities here…
Target design range = 80 miles spending 70%-80% between 55-65 mph.
This design would require significant power and capacity to achieve and the question about the aerodynamics of a VW bus becomes serious consideration.
An intermediate design (using recharging at airport parking lot) would reduce the design to 40 mile range spending 70-80% at 55-65 mph – much easy to achieve and similar to existing designs and builds found on the internet.
Starting the design considerations with this in mind will plan on specify components with good ranges above our initial application to allow growth in to hopefully the ideal design if not achievable in the first phase.
2012 Updates
Design changed driven by failing Lead Batteries (old) and exploded controller (Logisystems apparently are not as good as they claim)
2016 New England design
My daily commute is now 20 miles, with easy recharging options at the office. However strongly prefer to charge at home (cheaper) – existing design should cover this.
2026 Lithium refresh
After several years of on/off work, deciding to re-invest in solving the poor lithium performance. Aim is to replace battery pack as cleanly as possible (and BMS) targeting 80-90 mile range.
Design revisions
V1.0 DRAFT
Based on existing projects
| Motor | Net Gain Wrap 9 |
| Controller | Curtis 1231C |
| Batteries | Costco 115Ah/12v x 12 |
| Charger | Zivan NG 3 110/220 charger |
| Clutch | Yes |
V1.1 DRAFT
Refinements after discussion with David
| Motor | Net Gain Wrap 9 |
| Controller | Logisystems 144-156v 750A |
| Batteries | Costco 115Ah/12v x 12 |
| Charger | Manzanita Micro PCF 20 L30-6 connector |
| Clutch | Yes |
| Primary circuit | Fuse Contactor Manual disconnect (with driver operated cable) |
| Secondary circuit | Fuse Key-switch Inertia kill switch Charger interlock |
V1.2 – Implemented
Based on the battery selection, here is first on road implementation
| Motor | Net Gain Wrap 9 |
| Controller | Logisystems 144-156v 750A |
| Batteries | Max Rate AGM 12 x 12v |
| Charger | Manzanita Micro PCF 20 L30-6 connector |
| Clutch | Yes |
| Primary circuit | Fuse Circuit breaker Contacter (x2) Manual disconnect |
| Secondary protection circuit | Fuse Key-switch, Charger interlock (Brake interlock) |
| Secondary warning system | Motor overheat Charger interlock System ready Brush wear warning |
V2.0 – Project design (Upgrade to Lithium & replaced L30-6)
| Motor | Net Gain Wrap 9 |
| Controller | Logisystems 144-156v 750A |
| Batteries | GBS Lithium 48 x 3.3v BMS: Lithimate Lite |
| Charger | Manzanita Micro PCF 30 J1772 connector |
| Clutch | Yes |
| Primary circuit | Fuse Circuit breaker Contacter (x2) Manual disconnect |
| Secondary protection circuit | Fuse Key-switch Charger interlock (Brake interlock) |
| Secondary warning system | Motor overheat Charger interlock System ready Brush wear warning |
V2.1 – Project design (Replace controller)
| Motor | Net Gain Wrap 9 |
| Controller | Soliton Jr |
| Batteries | GBS Lithium 48 x 3.3v BMS: Lithimate Lite |
| Charger | Manzanita Micro PCF 30 J1772 connector |
| Clutch | Yes |
| Primary circuit | Fuse Circuit breaker Contacter (x2) Manual disconnect |
| Secondary protection circuit | Fuse Key-switch Charger interlock (Brake interlock) |
| Secondary warning system | Motor overheat Charger interlock System ready Brush wear warning |