Optimization of a 1974 VW Electric Bug

1
Optimization of a 1974 VW Electric Bug

• Michael Boyle
• Michael LaBeach
• Andrew Magaletti
• Rabei Rabei

2
Project

• Problems
• Hills
• Increase torque
• Speed
• Increase
• Range
• Increase
• Lights
• Interior

3
Concept Overview

• Battery Configuration
• 24V Field Charge
• Testing
• Battery Cages
• Rejuvenated Batteries
• Forced Air on Controller
• Air Induction for Motor
• Hydrogen Ventilation

4
Battery Configuration

• Addition of 6 batteries
• Increases range
• Series/Parallel
• Field Voltage Pack
• Increases speed
• Increases torque

5
Range Calculations and Testing
6
Speed Calculations and Testing
7
Power

• Graph shows the power required to achieve a
  certain speed.

8
Hill Climbing

• Hill Test
• 6.8 Grade
• 143 ft
• 72 Volts
• Variable Field Pack

9
Battery Cage

• Design
• Material - Steel A-36
• Cost
• Durable

10
Rear Battery Cage Analysis
11
Rear Battery Cage Stress Analysis
Stress Analysis
Displacement Analysis
12
Front Battery Cage Analysis
13
FEM Modeling
Stress analysis
Displacement Analysis
14
Controller Cooling

• Regulating Controller Temperature

15
Motor Air Induction

• Keep motor cool at 96V
• 240 cfm

16
Hydrogen Ventilation

• Fan Size
• Fan Mounting

17
Battery Rejuvenation

• Rob Matthies
• Process
• Analyze Battery
• Recondition Battery

18
Rejuvenation Process

• Analyze Battery
• Determine discharge rate
• Natural voltage

19
Rejuvenation Process

• Recondition Battery
• Use a battery re-conditioner
• Shake battery
• Charge, Discharge and Repeat
• Good Battery

20
Conversion Manual

• Motor
• Controller
• Charger
• Batteries
• Savings Calculations

21
Cost Analysis
22
Cage Materials
23
Conclusion

• On schedule
• All customer requirements expected to be met
• 91.40 under budget

24
Spring Proposal

• Start battery revival feasibility study
• Order parts
• Fabricate battery cages
• More testing
• Range
• Speed
• Torque

25
References

• Brant, Bob. Build Your Own Electric Vehicle. TBA
  Books, Blue Ridge Summit, PA. 1994
• Evalbum, (11/6/08), www.evalbum.com
• Barkley, Michael.(9/10/08) Mitsubishi Eclipse
  Conversion, (TexomaEV.com) http//www.texomaev.co
  m/ (Accessed 9/26/08)
• Volkswagen 1500 Technical Specifications,
  (Unique Cars and Parts) http//www.uniquecarsandpa
  rts.com.au/volks-wagen_1500_technical_specificatio
  ns.htm (Accessed 12/2/08)

26
Acknowledgements

• Rob Matthies
• Dr. Hollis
• Andrew Park
• Michael Barkley
• Dr. Clark
• Stephen DeBlois
• Keith Larson