jonescg
100 MW
Well it's only the fastest build log because it's the first time I've started a build log here on Endless-Sphere. If you want to read the whole lot from start to finish, look here: http://forums.aeva.asn.au/viewtopic.php?f=18&t=5502#p67017
But in a single post I'll document it here.
A friend asked me to convert her 1988 Honda Prelude, the one with the mechanical 4-wheel steering. I didn't want to, but suggested a few folks who might. They all said no, so she came back to me and begged me to do it. I warned her it won't be cheap, and it will take ages... and she said OK great!
So we took a few measurements and worked out what might fit, and made a selection of parts to go in. We decided on 24 kWh of LiPo pouches with a liquid cooling system to improve cell longevity. It wasn't going to be a race car, just a daily driver with a decent range for a sprawling metropolis like Perth.
I'd just bought my house, which has a big shed and room for a hoist. Once the hoist was installed, the car went up and out came the oily bits (December 16th, 2018). I had hoped to fit the whole battery where the fuel tank was, but we could only fit 6 modules there, and the last two modules would either have to go up the front under the hood, or in the spare wheel well of the boot. In the end, the boot was the only viable space.
The motor was a Greatland PMAC motor and controller, good for 60 kW peak and 30 kW continuous. Enough to get you rolling smartly, but not set the world alight. It was mounted to the original 5 speed manual gearbox. We retained the clutch because the gears are required for acceptable performance on take off.
It took it's first drive around the block 9 months later with just 6 modules installed.
https://www.youtube.com/watch?v=BcPlGSgthig
I now have all 8 installed, so the range is a comfortable 140 km or so. No real change in power, but we can change that later.
I initially used a sheet of aluminium honeycomb composite for the floor, but I wasn't happy with how fragile that stuff is should you ever drive over a big rock or something. So it has since been replaced with a floor of 6 mm plate aluminium. The flex gives rise to about a 6 Hz oscillation under certain circumstances, so hopefully the new coilovers will address some of that.
I'll have it on display at the Mosman Park Mens Shed craft fair this Sunday for Perth folks.
Basic stats:
Original chassis: 1988 Honda Prelude, mechanical 4-wheel steering, 2 litre petrol engine, 120 hp.
Original Tare: 1100 kg
New Tare: 1200 kg (or thereabouts)
New Power: 60 kW (80 hp)
Motor - Greatland PMAC liquid cooled motor, full use of front wheel drive transmission and differential.
Inverter - Greatland 3-phase inverter, liquid cooled.
Charger - 6.6 kW TC/Elcon charger, CAN controlled (eventually) single phase, 240 V AC, liquid cooled
DC/DC converter - 1.6 kW TC/Elcon, enable (12 V) activated
Charge port - Type 2 (mennekes) with AVC2 control. Doesn't work with most public charge points for some reason.
EVSE - Open EVSE kit with a 3-phase 32 A, 5-pin socket on the end.
Battery - 24 kWh high energy, liquid cooled LiPo pack. 96s10p of 7000 mAh cells from GE Battery, China. Assembled as 12s10p blocks using the screw termination kits I always use, plus liquid cooling plates on the underside of the cells. Nominal voltage: 355 V, fully charged at 400 V. The coolant is just water/glycol, but it is passed through a heat exchanger which is chilled with refrigerant from the air conditioning.
BMS - ZEVA EVMS3 with CAN Bus, current sensing and TC charger integration (very nice).
Range - in typical 60 km/h traffic, about 150 km. At 100 km/h sustained highway driving, about 110 km.
Regen - yes, but it's not working properly at the moment. About 7 kW of regen at the best of times.
Top speed - maybe 120 km/h in fifth, but it's not set up properly to get full power.
It will have been about 1 year since we started work in earnest, but hope to have it licensed before Christmas.
But in a single post I'll document it here.
A friend asked me to convert her 1988 Honda Prelude, the one with the mechanical 4-wheel steering. I didn't want to, but suggested a few folks who might. They all said no, so she came back to me and begged me to do it. I warned her it won't be cheap, and it will take ages... and she said OK great!
So we took a few measurements and worked out what might fit, and made a selection of parts to go in. We decided on 24 kWh of LiPo pouches with a liquid cooling system to improve cell longevity. It wasn't going to be a race car, just a daily driver with a decent range for a sprawling metropolis like Perth.
I'd just bought my house, which has a big shed and room for a hoist. Once the hoist was installed, the car went up and out came the oily bits (December 16th, 2018). I had hoped to fit the whole battery where the fuel tank was, but we could only fit 6 modules there, and the last two modules would either have to go up the front under the hood, or in the spare wheel well of the boot. In the end, the boot was the only viable space.
The motor was a Greatland PMAC motor and controller, good for 60 kW peak and 30 kW continuous. Enough to get you rolling smartly, but not set the world alight. It was mounted to the original 5 speed manual gearbox. We retained the clutch because the gears are required for acceptable performance on take off.
It took it's first drive around the block 9 months later with just 6 modules installed.
https://www.youtube.com/watch?v=BcPlGSgthig
I now have all 8 installed, so the range is a comfortable 140 km or so. No real change in power, but we can change that later.
I initially used a sheet of aluminium honeycomb composite for the floor, but I wasn't happy with how fragile that stuff is should you ever drive over a big rock or something. So it has since been replaced with a floor of 6 mm plate aluminium. The flex gives rise to about a 6 Hz oscillation under certain circumstances, so hopefully the new coilovers will address some of that.
I'll have it on display at the Mosman Park Mens Shed craft fair this Sunday for Perth folks.
Basic stats:
Original chassis: 1988 Honda Prelude, mechanical 4-wheel steering, 2 litre petrol engine, 120 hp.
Original Tare: 1100 kg
New Tare: 1200 kg (or thereabouts)
New Power: 60 kW (80 hp)
Motor - Greatland PMAC liquid cooled motor, full use of front wheel drive transmission and differential.
Inverter - Greatland 3-phase inverter, liquid cooled.
Charger - 6.6 kW TC/Elcon charger, CAN controlled (eventually) single phase, 240 V AC, liquid cooled
DC/DC converter - 1.6 kW TC/Elcon, enable (12 V) activated
Charge port - Type 2 (mennekes) with AVC2 control. Doesn't work with most public charge points for some reason.
EVSE - Open EVSE kit with a 3-phase 32 A, 5-pin socket on the end.
Battery - 24 kWh high energy, liquid cooled LiPo pack. 96s10p of 7000 mAh cells from GE Battery, China. Assembled as 12s10p blocks using the screw termination kits I always use, plus liquid cooling plates on the underside of the cells. Nominal voltage: 355 V, fully charged at 400 V. The coolant is just water/glycol, but it is passed through a heat exchanger which is chilled with refrigerant from the air conditioning.
BMS - ZEVA EVMS3 with CAN Bus, current sensing and TC charger integration (very nice).
Range - in typical 60 km/h traffic, about 150 km. At 100 km/h sustained highway driving, about 110 km.
Regen - yes, but it's not working properly at the moment. About 7 kW of regen at the best of times.
Top speed - maybe 120 km/h in fifth, but it's not set up properly to get full power.
It will have been about 1 year since we started work in earnest, but hope to have it licensed before Christmas.