eeVee Motors Tomorrow

1
eeVee MotorsTomorrows Electric Car today.

• Jerry Pohorsky
• Electric Auto Association
• Silicon Valley Chapter
• www.eaasv.org

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Overview

• About eeVee Motors
• eeVee Motors vision
• Flagship product 2001 Honda Civic conversion
• Other Products
• ThunderSky LiFePO4 batteries
• Elithion LithiuMate Battery Management System
  (BMS)
• Lithium-Powered Folding Electric Commuter Bicycle

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About eeVee Motors

• Started by 5 EAASV members
• Saw market need for AC Lithium conversions
• California Limited Liability Corporation (LLC)
• Self-funded, sweat equity
• Distributor for selected components
• Website www.eeVeeMotors.com

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Why drive an electric vehicle?

• No tailpipe no emissions
• Fuel with 100 domestic electricity
• Charge at night to get off-peak rates
• Combine with Solar to fight global warming
• Be a good citizen and example to others
• Get that EV grin

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eeVee Motors Vision

• Meet todays customer demand for professional
  quality electric vehicles at a reasonable price
  offer good value
• Use modern proven components for best combination
  of performance and reliability
• Offer room for four adults and full trunk space
• Go beyond the range of lead acid EVs while
  dropping weight and increasing performance

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Electric Vehicle Components

• Motor and adaptor plate Electro Automotive
• AC Motor Controller (Inverter) Azure Dynamics
• LiFePO4 Batteries Battery Chargers
• ThunderSky and ElCon
• Battery management system - Elithion
• Accessories and Instrumentation MES liquid
  heater, Quiet Vacuum Pump, Toyota Electric Power
  Steering pump, Electro Auto gages

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Trade - Offs to consider

• What are your driving needs? range, speed
• AC versus DC cost, reliability, performance
• Regenerative braking is it worth it for you?
• Battery and charger types range, cost, life
• Vehicle type weight, style, seating, cargo
• Cost Initial Price Total Cost of Ownership

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eeVee Motors choices

• Honda Civic 7th Generation (2001 2005)
• Best Selling car in America
• Room for 4 adults
• Range 75 miles or more
• Top Speed 75 MPH
• Recharge time 8 hours or less
• LiFePO4 for light weight, long life and safety

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Other considerations

• Keep the clutch for normal driving experience
• 300 volt battery pack for power and speed
• 90 Amp-hour batteries for range
• Well-engineered BMS for reliability
• Charger runs on both 120 and 240 Volts AC
• Batteries mounted low for better handling
• Batteries arranged to maximize cargo space
• Welded Steel battery boxes, crumple zones for
  safety

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Installing the electric motor
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Electric Motor installed in the car
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What about vehicle performance?

• Typical Range 30 40 miles (Lead-Acid)
• (How far do you drive each day?)
• Typical Range 70 100 miles (Lithium)
• Typical Top Speed 75 MPH
• Typical Battery Life 2 4 years (PbA)
• Typical Battery Life 8 10 years (Lithium)

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More about the batteries

• ThunderSky LiFePO4 cell specs 2,000 charge
  cycles _at_ 80 Depth of Discharge (DOD)
• 3,000 charge cycles _at_ 70 DOD
• Assume 100 DOD is 100 miles
• 80 DOD 80 miles 70 DOD 70 miles
• 80 miles x 2,000 160,000 miles (13 years)
• 70 miles x 3,000 210,000 miles (17 years)
• based on average mileage of 12,000 miles/yr.

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Battery Safety

• LiFePO4 batteries are safe will not catch fire
• Keep batteries under compression to avoid damage
  and early life failures
• Batteries must not be over charged or over
  discharged (BMS is the best insurance)
• Monitor battery temperature and turn on fans if
  needed (BMS can do this automatically)

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Energy Conversions

• 1 gallon of gasoline 115,000 BTU 33 kWh
• The EV1 electric car would store about the same
  energy as half a gallon of gasoline
• 300 Volts x 90 Amps x 1 hour 27 kWh
• RAV 4 EV 288 volts x 95 Amp-hours 27 kWh
• Range of RAV 3 EV is about 100 miles
• At 250 Wh/mile, 100 miles uses 25 kWh

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Tips for a successful conversion

• Project Notebook
• Repair manual for car model you choose
• Detailed Planning time, parts, cost
• Test as you go
• Take photos picture is worth 1000 words

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How much will it cost?

• Parts about 15 K (AC) plus accessories
• Batteries 10 - 15 K (Li-Ion)
• Labor 80 800 hours
• Tools, equipment, shop rental price varies
• Automotive tools drills, wrenches, etc.
• Electrical Test Equipment,
• DVM (Digital Voltmeter, Digital Multi-Meter)
• Clamp Ammeter

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Choosing the donor vehicle

• Curb Weight less than 2,500 lbs is ideal
• Honda Civic is about 2,400 lbs.
• Older Models are often best (pre-2000)
• Body and frame in good condition no rust
• Standard transmission clutch is best
• Accessories options
• Power Brakes, Power Steering, Heat AC

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Preparing ICE car for Conversion

• Remove Engine, gas tank, muffler, etc.
• May be able to sell parts removed
• Label all wires and document in notebook
• Save all brackets may come in handy
• Beware of sharp sheet metal
• Paint exposed metal to prevent future rust

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Electric Drive systems AC or DC?

• AC more efficient and more expensive
• DC simpler and less expensive
• AC often has regenerative braking
• DC systems typically use half the voltage but
  twice the current (affects wire size)
• DC systems have lower RPM (more shifting of gears
  is required)

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Motors

• DC Motors 9 inch or more best for gt 60 MPH
• AC Motors 50kW or more recommended
• Can use two motors if needed
• Need to match motor and controller (inverter)
• Look at the EV Album to see what motors are used
  for the type of car you want to convert
• www.evalbum.com (Search by Type/Make)

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Motor Controllers and Inverters

• DC 400 Amps to 2,000 Amps
• AC matched to motor (20 kW to 150 kW)

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Battery Tradeoffs

• Cost, Cycle Life, Capacity, Weight, Size
• Exotic NiCad, NiMh, Li-Ion Cost 10k - 20k
• Protect your investment with BMS (Battery
  Management System)
• Lead Acid (PbA) Deep Cycle, Cost 2k - 6k
• Flooded are very forgiving (no BMS)
• Sealed types include AGM, Gel, FireFly (foam)
• Voltage tradeoffs for 6V, 8V, 12V (weight vs.
  range)
• EAA Discount at American Battery Company
• Jim Ramos, Hayward, CA. - Call 510-259-1150
• eeVee Motors sells ThunderSky Lithium
  batteries59-10- 259-1150

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Power Steering Brakes

• Swap to manual rack lowest cost option
• Electric motor for power steering pump
• Power brakes electric vacuum pump
• We use a powerful but quiet vacuum pump

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Heating and Cooling

• Reduces range depending on usage
• Fluid filled heater preserves look and feel
• Existing Air Conditioning compressor powered by a
  small electric motor

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Suspension and tire modifications

• Goal restore original ride height
• Heavy duty shocks air bags for load leveling
• Goal longer range low rolling resistance tires
• Tire pressure monitoring system (optional)

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Reducing Rotating Mass

• Removing 1 pound of rotating mass has the same
  effect on acceleration as removing 100 pounds of
  weight from the car
• Original Honda steel flywheel weighed 14 lbs.
• Replaced with aluminum flywheel (7 pounds)
• Also replaced clutch donor car had 149 K miles
  at time of conversion

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How far can the eeVee Motors Honda Civic go on a
charge?

• Battery Pack capacity is as follows
• 90 AH x 3.2 V x 96 cells 27,648 watt-hours
• 80 DOD 22,118 watt-hours
• 22,118 watt-hours/250 watt-hours/mile 88 mi.
• Slower driving will improve range
• Frequent stops, hills, hard acceleration and/or
  high speeds will reduce range

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Power consumption

• Whats a watt-hour?
• 1 volt x 1 amp x 1 hour
• Typical electric cars use 250 watt-hours per mile
• A 10 mile drive requires 2,500 watt-hours
• A 80 mile drive requires 20,000 watt-hours

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Elitihion Master BMS Controller
One data cable connects each bank to the Master
BMS controller. The eeVee Motors Civic Electric
car has 96 cells in 3 separate battery boxes.
The 96 cells are divided into 7 banks.
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Elithion BMS Cell Boards No Spaghetti
design Each cell board sits on top of one 3.2
volt cell.
Elithion BMS Wiring
Spaghetti BMS Wiring from competitor
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BMS Features

• Balances batteries while charging
• Shuts off charger if needed
• Low voltage protection while driving
• Cell voltage and current monitoring
• Temperature monitoring
• Fault alarm
• Can reduce performance smoothly if needed

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In Conclusion

• Questions and Answers
• Web links
• www.eeVeeMotors.com
• www.liionbms.com
• Thank you.