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