Electric Vehicles 101 Jesse Tufts, P.Eng. EV 101 Overview - - PowerPoint PPT Presentation

Electric Vehicles 101

Jesse Tufts, P.Eng.

EV 101 Overview

• Introductions
• Safety
• Glossary
• Why EVs? Why Not?
• Factory Offerings
• DIY Evs, Why? Why Not?
• DIY EV Expectations
• EV Components
• Range and Performance Estimation
• Economics
• Example builds
• Resources

Introductions

• Jesse Tufts
• Mechanical Engineer - U of S

2006

• Formula SAE alumni
• Grew up on a farm, started off

with classic cars

• Started a Japanese Mini Truck

EV conversion in 2010

• It's now my daily driver!

The Electric Japanese Mini Truck

• 1992 Daihatsu Hijet Jumbo Cab
• Joint project with John Storey Bishoff

The Electric Japanese Mini Truck

• Then
• 660cc 3 cylinder gas motor, about 45hp
• 4wd, 5 speed transmission
• 7 L/100km fuel economy (42mpg)
• Now
• 45hp three phase AC motor
• 7.6kWh lithium battery pack
• 60 km max city range
• 85 km/hr top speed

The Electric Japanese Mini Truck

• Joint project, shared use truck
• Started February 2010
• Licensed in Spring 2012
• 1000 + hours and counting!
• $14,000 total cost including the truck
• $0.01/km electricity cost to drive
• Very fun to drive! Great for hauling stuff

The Electric Japanese Mini Truck

Introductions

• Who?
• Where?
• What?
• Why EVs?
• Plans?

Safety Disclaimer!

• DIY EVs can be dangerous
• Fire
• Electrocution
• Crush injuries, you name it!
• 0.2A across your heart can kill you
• EV batteries can often provide >1000A!
• High voltage increases shock potential
• Wear gloves when doing any wiring and don't become

part of a circuit!

• Keep yourself and others around you safe

Glossary

• Kwh
• unit of energy commonly used to measure

electricity consumption and capacity.

• Equivalent to 1000 W of power (1 kW)

running for 1 hr, or 3,600,000 J.

• Electric Current (I)
• measured in amperes, the fow rate of

electric charge, 1A = 1 coulomb/sec or 6.24 x 10

18 electrons/sec.

• Analogous to water fow rate ex. L/min

Glossary

• Voltage (V)
• The electrical potential difference between two points.
• Analogous to water pressure, ex. psi.
• Power (P)
• measured in Watts, 1W = 1J/sec
• P=IV, electric power = electric current x voltage
• Rate at which energy is used or work is performed
• Shaft power = Torque x angular velocity
• Angular velocity radians/sec
• 2π radians/revolution
• Torque in Nm
• Power(W)=(Nm x rpm)/2π
• Power(Hp) = (ftlbs x rpm)/5252
• 1 Hp = 746W

Why Electric Vehicles?

• Personal Transportation is part of our way of life
• Current gas and diesel vehicles are very

ineffjcient

• Ex. 3rd gen Prius = 38.5% thermally effjcient
• 61.5% energy wasted as heat!
• Typical modern car – 25% to 30% thermally

effjcient in ideal conditions

• Narrow RPM range necessitates complicated

transmissions

• Inherently noisy with lots of vibration

Why Electric Vehicles?

Why Electric Vehicles?

• Burning fossil fuels = emissions
• CO2, N2O, SO2, unburned hydrocarbons,

particulate matter

• Source of environmental and health problems.
• Extraction and refjning create Social, Health and

Environmental problems

• Fossil fuels are undeniably needed but why are

we wasting them?

• What happens when we run out?
• Can we afford to burn them until they run out?

Why Electric Vehicles?

• Bio-fuels can offer a partial solution if done

properly

• Diffjcult to change fuel sources on existing vehicles
• Food vs. Fuel?
• Still almost impossible to be energy independent
• Nearly impossible to brew your own gasoline
• Home brew bio diesel and SVO is possible but

require a large land base to grow oil crops

• Current waste oil sources could only provide a

small % of needed transport fuels

Why Electric Vehicles?

Why Electric Vehicles?

• Electric vehicles offer very high energy effjciency –

80%-95%

• Zero tailpipe emissions, potentially 100% pollution free
• Very quiet operation with almost no vibration
• Very wide effjcient RPM range and full torque at 0 rpm

means no transmission is needed

• Electric motors have one moving part, almost no

maintenance

• ~1/10th the cost to operate compared to a gas car
• Electric motors will happily accept power from any

source

Why Electric Vehicles?

• Electricity is a universal source of energy that can be

generated many different ways

• Solar, Wind, Hydro, Geothermal offer pollution free

power generation and almost unlimited capacity!

• Natural Gas power plants can operate at >2X the

effjciency of a gas engine at peak conditions

• 4X the effjciency at typical conditions!
• Large stationary power plants are better able to deal

with emissions than cars.

• Power is already delivered right to your garage

http://shrinkthatfootprint.com/wp-content/uploads/2013/02/Shades-of-Green-Full-Report.pdf

Why Electric Vehicles?

• It is entirely possible and practical to generate

enough electricity to cover household and transportation needs on the land area of a single family home. Personal Energy Independence is Possible

Why Not Electric Vehicles?

• Current battery technology means range is somewhat

limited for now

• Charging infrastructure is not yet widespread
• Current charging technology is slow when compared to a

gas fjll-up

• Not all electricity sources are “green”
• Still uncertain long term reliability
• Currently not practical for large, long range, heavy haul

vehicles

Why or Why Not Electric Vehicles?

• What do you think?

Factory Electric Vehicles

• If you're going to buy a

new car anyways....

• Currently Available

– Nissan Leaf – Mitsubishi IMiEV – Ford Focus Electric – Smart Fortwo EV – Tesla Model S – Fiat 500e – Honda Fit EV – Toyota Rav4 EV

– Chevrolet Spark EV – Chevrolet Volt

Nissan Leaf

– Type: Battery Electric – 4 door hatchback, 5

Passenger

– Range: 120km (EPA) – 200km (NEDC) – Effjciency 193Wh/km city – 230Wh/km hiway – 107Hp, 187 lbft torque – ~10 sec 0-100km/hr – 3.6kW or 6.6kW Chargers – CHaDEMO fast charging

equipped, 80% in 30 min.

– 24 kWh battery pack

– Available in Edmonton – Best selling EV

worldwide, 83,000 total sales as of Sept 30th, 2013

– Starting price $31,698 – Video

Mitsubishi iMIEV

– Type: Battery Electric – 4 door hatchback, 4

Passenger

– Range: 100km (EPA) – 150km (NEDC) – Effjciency 168Wh/km city – 211Wh/km hiway – 66Hp, 145 lbft torque – ~13 sec 0-100km/hr – 3.6kW on board charger – CHaDEMO fast charging

equipped, 80% in 15 min.

– 16 kWh battery pack – Available in Edmonton – Starting Price $32,998 – Video

Ford Focus Electric

– Type: Battery Electric – 4 door hatchback, 5

Passenger

– Range: 122km (EPA) – 162km (NEDC) – Effjciency 193Wh/km

city

– 215Wh/km hiway – 143Hp, 184 lbft torque – ~9.5 sec 0-100km/hr – 6.6kW on board charger – No Fast Charging – 23 kWh battery pack – Available in Edmonton – Starting Price $41,199 – Video

Smart fortwo EV

– Type: Battery Electric – 2 door hatchback, 2

Passenger

– Range: 109km (EPA) – 135km (NEDC) – Effjciency 173Wh/km

city

– 226Wh/km hiway – 74Hp, 96 lbft torque – 11.5 sec 0-100km/hr – 3.3kW on board charger – No Fast Charging – 17.6 kWh battery pack – Available in Edmonton – Starting Price $26,990 – Video

Tesla Model S

– Type: Battery Electric – 4 door hatchback, 7

Passenger

– Range: 335/426km (EPA) – 390/502km (NEDC) – Effjciency 222Wh/km city – 217Wh/km hiway – 302/362/416Hp, 325/443

lbft torque

– 6.2/5.6/4.4 sec 0-

100km/hr

– 10/20kW on board charger – 120kW Supercharging

– 60/85 kWh battery pack – Available in Edmonton – Starting Price $77,800 – Video

Fiat 500e

– Type: Battery Electric – 2 door hatchback, 4

Passenger

– Range: 139 km (EPA) – Effjciency 173Wh/km

city

– 195Wh/km hiway – 111 Hp, 147 lbft torque – 9 sec 0-100km/hr – 6.6kW on board charger

– 24 kWh battery pack – Only available in

California...

– Starting Price $32,500

US

– Video

Honda Fit EV

– Type: Battery Electric – 4 door hatchback, 5

Passenger

– Range: 131 km (EPA) – Effjciency 160Wh/km

city

– 201Wh/km hiway – 134 Hp, 189 lbft torque – ~9 sec 0-100km/hr – 6.6kW on board charger – 20 kWh battery pack – Lease Only in select US

markets

– Video

Toyota Rav4 EV

– Type: Battery Electric – 4 door SUV, 5 Passenger – Range: 165 km (EPA) – Effjciency 270Wh/km

city

– 285Wh/km hiway – 154 Hp, 270 lbft torque – ~7 sec 0-100km/hr – 10kW on board charger – 41.8 kWh battery pack – $49,800 US, for sale in

California only

– Video

Chevrolet Spark EV

– Type: Battery Electric – 4 door hatchback, 4

Passenger

– Range: 132 km (EPA) – Effjciency 165Wh/km

city

– 193Wh/km hiway – 140 Hp, 400 lbft torque – 7.5 sec 0-100km/hr – 3.6kW on board charger – SAE Combo Fast

Charging 80% in 20 min.

– 21.3 kWh battery pack – $26,685 US, for sale in

California and Oregon,

– Available for feet sales

• nly in Canada

– Video

BMW i3

– Type: Battery Electric +

• ptional range extender

– 4 door hatchback, 4

Passenger

– Range: 128-160km est – Effjciency 165Wh/km

city

– 193Wh/km hiway – 170 Hp, 184 lbft torque – 6.9 sec 0-100km/hr – 7.4kW on board charger – SAE Combo Fast

Charging 80% in 20 min.

– 22 kWh battery pack – $44,950 available

summer 2014 in Canada

– Video

Chevrolet Volt

– Type: Extended Range

EV

– 4 door hatchback, 4

Passenger

– Range: 61 km (EPA) – Effjciency 214 Wh/km

combined

– 149 Hp, 272 lbft torque – 9 sec 0-100km/hr – 3.3kW on board charger. – 1.4L, 80hp gas motor – 16.5 kWh (10.8 kWh

usable) battery pack

– $36,895 – Video

Up and Coming

• Tesla Model X
• Tesla SUV, 4wd, seats 7
• Cadillac ELR
• Sporty and luxurious Volt?
• VW Golf Electric, BMW i3,
• Also worth mentioning are the Ford C-Max

Energi and the Ford Fusion Energi.

Up and Coming

• What have you heard of?

Other Options?

• There are occasionally EV conversions and, more

frequently now, factory EVs on the used market.

• DIY Conversion is possible
• Parts are available to convert an existing vehicle

into a battery EV

• Almost any vehicle can be converted

Why DIY Conversion?

• Potentially cheaper than Production EVs
• More vehicle selection
• Vehicle confjguration is only limited by your

imagination (and your wallet)

• High performance potential
• Satisfying hobby, with a conscience!
• The more people who see EVs as viable the more

they will grow

Why Not DIY Conversion?

• Potentially more expensive than Production EVs
• Can be time consuming to convert
• Will you actually fjnish this project?
• Vehicle reliability is limited by your skill
• Low performance potential
• Can be technically diffjcult
• Like any DIY project there is potential for safety

hazards!

Great Expectations

• Vehicle Type
• Range
• Performance
• Budget
• Tools, Facilities and

Skills

Vehicle Type

• 1. How many passengers?
• Any kids on the way?
• 2. How much cargo?
• Do you need to haul more than groceries?
• 3. What type of driving?
• City vs. Highway
• 4. Has it been done before?
• 5. What do you want to drive?
• Do you want to invest $20,000 in a beater?

Range Expectations

• 1. How far do you really need to drive in a day?
• EVs are great for commuting!
• 50km = easy, lower cost
• 100km = reasonably attainable
• 200km = possible but getting quite expensive
• 2. Could you charge at work?
• 3. Longest daily drive has to be less than 80% of

your maximum range!

Performance

• 1. Top speed
• Aerodynamics
• Gearing
• Max motor RPM
• Power
• 2. Acceleration
• Weight
• Gearing
• Torque
• You want 0.5G min off the line!

Budget

• What's the maximum you're comfortable spending on this

project?

• Donor cost vs. parts cost; is the vehicle worth spending a

lot of money on?

• Can you meet your range and performance expectations

with your selected donor vehicle and budget?

• Can you sell parts removed from the donor?
• Could you share the project with a friend?

Tools, Facilities and Skills

• Tools you'll need
• Full set of typical mechanics and fabrication tools
• Voltmeter, Electrical crimpers and wire stripper
• Tools that will be good to have or borrow
• Welder, drill press, band saw
• Engine hoist
• You'll need an enclosed garage with good lighting and a

heater

• Skills
• Can you do basic car maintenance?
• Do you have a basic knowledge of electricity and wiring?
• Do you have access to a friend who can lend a hand?

EV Components

• Motors
• Adapters and drivetrain
• Controllers
• Batteries
• Battery Management Systems
• Chargers
• Auxiliaries
• DC-DC converter
• Vacuum Pump
• Power Steering
• Heater

AC Motors

• Smooth power and control, easy reversing
• No maintenance, high effjciency
• Full torque regenerative braking
• Somewhat limited options, DIY versions are less powerful

and more expensive than DC motors

• One main brand for DIY, HPEVS motors with Curtis AC

controllers

DC Motors

• Very high torque and power potential!
• Lots of size and brand options, less expensive than AC for a given

power output

• Most types can not provide regenerative braking
• Brushes require some regular maintenance
• Brands include NetGain Motors, Advanced DC, D&D Motors, Kostov

Adapters and Drivetrain

• Adapters
• Attach the motor to the

transmission input shaft

• Can be purchased or

custom machined

• But, alignment is critical!
• Drivetrain
• Standard transmission vs.

direct drive

• 4wd can work, but expect

less range

Motor Controllers

• Higher Amps = Higher Torque
• AC
• Curtis 650A, 60 - 130V max
• 75kw max power
• Curtis 500A 60-170V max
• 85kW max power
• All PC programable

Motor Controllers

• DC
• Evnetics Soliton Jr. - 600A, 9-

340V max

• Soliton 1 – 1000A, 9-340V

max

• Soliton Shiva – 3000A, 425v,

1.2MW!

• PC programable, liquid cooled
• Other brands include Curtis,

Netgain Controls, Zilla

Batteries

• Typical Pack Voltage 96V-144V
• Lead Acid
• Heavy
• Low effjciency (60%)
• Low usable capacity
• Wear out quickly (500 charge cycles)
• Some types need maintenance
• Cheap, easy to implement
• Work well for lawn tractor or quad

conversions

Batteries

Lithium Iron Phosphate

• Best chemistry for DIY

conversions

• 1/3 the weight for double the

usable capacity of lead!

• Effjciency from 88%-95%
• >1500 charge cycles if you

typically discharge to 80% DOD.

• 3.2V/cell
• Popular brands; CALB, Winston,

Sinopoly, Headway

• Rated in Ah, common 60-400Ah

Batteries

• Lithium Iron Phosphate
• Don't Overcharge! <3.6V
• Don't Over Discharge! >2.5V
• Don't charge below freezing
• Max 3C continuous discharge, for a

100Ah cell that's 300A

• Capable of >10C short discharges
• Safe to use at -30 but performance is

poor!

• Highly recommended to use a BMS

(Battery Management System)

Batteries

• Sinopoly 100Ah Cell
• Calb Cell Curves, charge, discharge

etc.

Battery Management Systems

• Monitor individual cell voltages to

prevent overcharging

• Bleed energy off high cells to balance

the pack, commonly use a power resistor

• Provide low voltage warnings to

prevent over discharging

• Helps diagnose a weak or defective

cell

Battery Management Systems

• Commonly used include

Mini BMS

• Elithion
• Also check out the BMS Directory

Battery Chargers

• Start under $500 for a simple 1.5

kW charger

• Up to 12 kW chargers available
• Small packs can charge off 12 V

but larger packs need a 240 V charger

• Popular brands include Elcon,

Manzanita Micro, Zivan, DeltaQ

Battery Chargers and Accessories

• 12kW open source charger
• 15kW open source home

charging station

• Android Based EV Dashboard
• Cycle Analyst e-guage

Auxiliary Components

• Large vehicles need power brakes and power steering
• Electric vacuum pump for power brakes
• Electric hydraulic pump for power steering
• DC-DC converter provides 12 V to power your vehicle's

systems

• Electric Heat
• Use a ceramic heater core, 3000 W minimum
• Heated seats only draw 60 W each! Add on kits

are available

• Potential to preheat your vehicle while it's

plugged in

Fitting it All Together

Fitting it All Together

Performance Estimation

• You want 0.5G acceleration off the line!
• If you could maintain 0.5G acceleration up to

100km/hr you would get there in 5.7 sec!

• Motor torque x gear ratio = wheel torque
• Wheel torque ÷ tire radius = forward thrust
• Forward thrust ÷ vehicle weight = acceleration in Gs
• At what speed does the motor torque decrease?
• Use this to size your motor and controller

Estimating Range and Sizing the Pack

• Gas Car Effjciency:
• Only 14-16% in the city!
• 20-26% on the highway
• Gasoline energy content = 9.63 kWh/L
• Electric car effjciency: 80-90% !
• Use this to estimate the electrical energy

needed to drive an EV a given distance

• Size the pack or estimate range with this

value

Example Build: Toyota Echo Hatchback

• Pro's
• Lightweight – 2080 lbs
• Aerodynamic – 0.29 drag

coeffjcient

• 4 doors
• Inexpensive to buy used
• Reasonably modern
• Simple reliable car
• Cons
• Not terribly exciting!

Yet....

Vehicle Type

• 1. How many passengers? (4)
• Any (more) kids on the way? (Not Yet)
• 2. How much cargo? (Just Groceries)
• I can use the mini truck for larger cargo
• 3. What type of driving? (City)
• 4. Has it been done before? (Yes!)
• 5. What do you want to drive?
• A Tesla Model S.....

Range Expectations

• 1. How far do you really need to drive in a day?
• Spruce Grove and back safely = 60 km highway
• 2. Could you charge at work? (Potentially)
• 3. Longest daily drive has to be less than 80% of

your maximum range!

• No problem, typical day <40 km

Performance

• 1. Top speed (120 km/hr)
• Aerodynamics (good)
• Gearing (5 spd manual)
• Max motor RPM (6500)
• Power (105 hp original)
• 2. Acceleration
• Weight (2080 lbs original)
• Gearing (5 spd manual)
• Torque (electric will have more than stock!)
• 0.5G off the line acceleration? We'll see...

Budget

• What's the maximum you're comfortable spending on this

project? ($20,000 including the car)

• Donor cost vs. parts cost; is the vehicle worth spending a lot
• f money on? (Yes)
• Can you meet your range and performance expectations

with your selected donor vehicle and budget? (We'll See!)

• Can you sell parts removed from the donor? (Yes)
• Could you share the project with a friend? (Possibly)

EV Components

• Motors – AC51
• Adapters and drivetrain

– From CanEV, standard trans FWD

• Controller – Curtis 500A
• Batteries – 48 x 100 Ah Sinopoly
• Battery Management System

– Mini BMS

• Chargers – 1.5 kW Elcon
• Auxiliaries
• DC-DC converter – 30 A
• Vacuum Pump - yes
• Power Steering – manual steering available
• Heater – 3 kW min + add on heated seats!

Performance Estimation

• AC 51 Motor torque = 100 ft lbs from 0-4500 rpm
• 100 ft lbs x 12.5:1 gear ratio in 1st = 1250 ft lbs wheel

torque

• 1250 ft lbs x 12”/11.5” tire radius = 1304 lbs thrust
• 2200 lb estimated car weight
• 1st gear = 0.59G up to 40 km/hr (4500 rpm) in <2 sec!
• 2nd gear = 0.32G up to 73 km/hr (4500 rpm) in 6.5 sec

with no shift. ~5 sec with a shift.

• Motor revs to 8000 rpm (with reduced torque) so you

should be able to drive in just 2nd gear and still hit 100+km/hr.

• Zippy performance in the city: Check!

Range Estimation

• Pack Size = 48 x 100 Ah Sinopoly = 154V nominal
• 154V x 100 Ah = 15.36 kWh pack size
• City fuel economy = 6.7 L/100 km city
• 6.7 L/100 km x 9.63 kWh/L = 0.645 kWh/km = Energy burned
• 0.645 Wh/km x 15% (city effjciency) = 0.097 kWh/km

= Mechanical energy needed

• 0.097 kWh/km ÷ 80% (EV effjciency) = 0.121 kWh/km

= Electrical energy needed in the city

• 0.164 kWh/km on the highway
• 15.36 kWh ÷ 0.121 kWh/km = 127 km max city range
• 100 km safe city range, 75 km safe highway range

Cost Estimate

• AC 51 Motor / Curtis 1239 Controller
• $4,425
• Motor Adapter
• $850
• 48 x 100Ah Sinopoly Cells
• $6,480
• Battery Management System
• $700
• 1.5 kW Charger
• $400
• Accessories (DC-DC, Vacuum Pump, Instrumentation, Wiring,

Metal work, etc.)

• $1,500
• Total = $14,355, Typical used Echo - $5,000

• Value of the EV grin you'll have after your fjrst drive?

Priceless!

Cost Estimate

• Cost to drive
• Assuming 50% city/50% highway
• Energy consumption from the pack =0.143

kWh/km

• Charger effjciency 87%
• From the wall consumption = 0.164 kWh/km
• Electricity cost $0.08/kWh
• 1.3 cents/km!
• With heater use and all that available torque....
• Add 30% = 1.7 cents/km for electricity
• No oil changes, minimal brake use due to regen

Economics

• Cost to drive the original gas car
• Assuming 50% city/50% highway
• 6.7L/100km city, 5.6L/100km highway
• 6.2L/100km average
• Average fuel price $1.12/L
• 7 cents/km + ~30% winter driving and

increasing fuel prices over time

• 9 cents/km typical
• Oil changes $50/5000km = 1 cent/km
• Brakes/engine maintenance ~$500/50,000km? =

1 cent/km

• Total $0.11/km

Economics

• Savings
• 11-1.7 = 9.3 cents/km
• $14,355/$0.093/km = 154,355 km till payback
• This gets a lot better if you switch from something like

a truck!

• How much better?
• Battery lifespan and cost/km?

Economics

• Check out my blog
• Links to useful EV websites
• This presentation in PDF format.

www.jessetufts.wordpress.com

Resources

Questions?