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ELECTRIC VEHICLE TECHNOLOGY David Brandt, P.E. The Basics: • EV: electric vehicle • Are EV’s practical? Golf courses and airports have thought so for many years. • But what about on the road? Are there EV’s among us? Yes, and not just in California! • Is there actually technology available to you and me to allow us to operate a practical EV? Yes! OEM EV’s (you may have heard of some of these): • GM EV1 OEM EV’s: • Solectria Force OEM EV’s • Corbin Sparrow PTV Hobbyists? • The hobbyist says “If I can’t buy one, I’ll build my own… • Honda Civic More Hobbyist EV’s • My Escort More hobbyist EV’s • Ford Ranger Components • What is out there that you need to have to build an EV (besides batteries)? – – – – – – – – Motor Controller Charger DC/DC Converter Heater Instrumentation Contactor(s) Safety Equipment Motors • OEM’s: typically AC drive – Fail-safe design – Low initial torque, higher at speed – requires complicated electronics package • • • • AC speed control (similar to industrial) Inverter (convert DC to AC) High voltage (240-350 VDC) Bearings only mechanical maintenance item Motors • Hobbyist: typically brushed DC series wound – – – – – – Motors are available and inexpensive 100% torque at 0 RPM Controllers are dirt cheap compared to AC No inverter stage required Lower voltage system (72-156 VDC) Bearings and brushes are potential maintenance items (change brushes every 100,000 hours or so) Motors • “Advanced DC” 9” diameter motor • Others include GE, Prestolite Controllers • In General, Volts = Speed, Amps = Torque – Curtis • to 144 VDC, 500 Amps – Auburn Scientific • to 192 VDC, 1200 Amps – DCP • to 336 VDC, 600/1200 Amps – EVCL • “GODZILLA” to 336 VDC, 1200 Amps Controllers • All use PWM technology. Chargers • OEM: uses weird connectors like inductive “paddle” or AVCON “gas pump” nozzle. • Hobbyist: How about something everyone already has, like 120 VAC household outlets and 240 VAC dryer outlets? • Simple (voltage regulated) to complicated (computer controlled charging algorithms) • More advanced charging required for advanced batteries (AGM) DC/DC Converters • Uses PWM to step traction pack voltage down to 12V to run car accessories. • Common in electronics use • Not widely available in the voltages required Heater • Ceramic - Self-regulating temperature of about 180° F. • As temp. increases, resistance increases, decreasing power and stabilizing temp. • Therefore, more air across the element = more heat. • Typically 1500W. Can be stacked for more heat. Heater • The right type can be “harvested” from an AC ceramic heater. Instrumentation • Instrumentation can be as simple as an expanded scale voltmeter, but can be sophisticated, and include: – – – – Traction Pack Voltmeter Battery Current Ammeter Motor Current Ammeter Amp-hour/kWh meter (“E-Meter”) Contactors • BIG relays for switching traction pack Safety • Inertia switch to deactivate contactor(s) – same as is used to shut off fuel pumps in ICE cars • • • • AGM batteries - no spillage Service disconnects - BIG circuit breakers Fuses, of course Traction pack is electrically isolated from frame • 8 G crash load rating recommended for battery boxes Performance • Acceleration and speed – – – – About the same as ICE Ranges from “economy car” to “muscle car”. DC motors great for drag racing Current NEDRA record 8.801 seconds in the 1/4 mile by “Current Eliminator” Performance • tZero by AC Propulsion Performance - tZero • AC Propulsion's tzero out-accelerated a Ferrari F355, a new Corvette, and a Porsche Carrera 4 in a series of impromptu 1/8 mile drag races held on January 22, 2000 at Moffett Field in Mountain View, California, and at Calstart's northern facility at the former Alameda Naval Air Station. Performance - tZero • tZero mfg. By AC Propulsion versus Corvette Performance • Range - typically 30-60 miles – somewhat dependent on if you have a lead foot – great for commuting, which is where people use the most gas anyway. – Use an ice vehicle for long trips - the right tool for the right job. • Over 100 miles attainable with purposebuilt EV’s or using advanced batteries Performance • John Wayland’s 120 mile range “Red Beastie” Performance • “Red Beastie’s” battery pack Emissions • Common claim is EV’s just move the pollution • Point taken, but power plant emissions are scrubbed to a point not possible on a vehicle. Emissions • Belfast electric bus project (4 year duration of monitoring) Fuel Consumed (kWh/mile) Diesel Electric Savings 4.9 2.2 55% Pollutants (gms/mile) CO2 CO NOx+SO2 Hydrocarbons Particulates Diesel Electric Savings 1331 1058 21% 7.64 0.18 98% 19.96 11.52 42% 2.74 0.18 93% 5.1 0.2 96%