ATV conversion (mostly done)

Electric cars, trucks, ATVs, NEVs - things bigger than a motorcycle.
Post Reply
romelec   10 W

10 W
Posts: 90
Joined: Mar 11 2011 3:46pm
Location: Marseille, France

ATV conversion (mostly done)

Post by romelec » Jan 03 2018 11:42am

Hi,

I started to work on my ATV conversion about 4 years ago (with a lot of long pauses), finally last week I could do the first test:


The ATV is a Jianshe 250 bought about 10 years ago for 2000€

Motor: used ME1114 with regular hall sensor instead of the sin/cos, with a pulley and universal joint to the original transmission shaft
_DSCN3004.jpg
_DSCN3004.jpg (151.52 KiB) Viewed 2300 times
Controller: Sevcon gen 4 size 4 on ebay, with the old IXXAT interface (I don't sell it !)
Motenergy provided me a configuration file they use on a test bench, it was certainly not easy to make it working but I didn't had to modify the difficult settings such as the PI control loop parameters.

Batteries: 10Ah headway cells to form a 72V 60Ah pack
I have also 4 headway cells for the accessory battery and a 12v converter
_DSCN3412.JPG
_DSCN3412.JPG (119.03 KiB) Viewed 2300 times
_DSCN3413.JPG
_DSCN3413.JPG (113.8 KiB) Viewed 2300 times


BMS: the last model from foundingpower bought before they stopped
_P1050834.jpg
_P1050834.jpg (111.04 KiB) Viewed 2300 times
Throttle: I used a thumb throttle modified with 3d printed parts to use a cable so I can keep the original thumb throttle
_P1050836.jpg
_P1050836.jpg (98.13 KiB) Viewed 2300 times
Everything fits very very tightly:
_DSCN3416.JPG
_DSCN3416.JPG (117.95 KiB) Viewed 2300 times
_DSCN3417.JPG
_DSCN3417.JPG (107.25 KiB) Viewed 2300 times

romelec   10 W

10 W
Posts: 90
Joined: Mar 11 2011 3:46pm
Location: Marseille, France

Re: ATV conversion (mostly done)

Post by romelec » Jan 03 2018 11:48am

The things to finish are mostly around the Sevcon programming:
- figure out how to have regen on throttle release
- add a brake lever for variable regen, I will use an hydraulic one with a pressure sensor
- eventually setup the 3 different profiles with different power / regen levels
- find how to link the BMS to the Sevcon

User avatar
skeetab5780   10 MW

10 MW
Posts: 2127
Joined: Jun 15 2009 10:58pm
Location: MA
Contact:

Re: ATV conversion (mostly done)

Post by skeetab5780 » Jan 03 2018 12:38pm

Awesome build sub’d

Always wanted a two wheel drive sports quad conversion myself, all time favorite quad is 1987 trx250x

User avatar
fechter   100 GW

100 GW
Posts: 12913
Joined: Dec 31 2006 3:23pm
Location: California Bay Area, USA

Re: ATV conversion (mostly done)

Post by fechter » Jan 03 2018 2:27pm

Wow, looks like it runs great. Nice work.
"One test is worth a thousand opinions"

Hillhater   100 GW

100 GW
Posts: 9255
Joined: Aug 03 2010 10:33pm
Location: Sydney ..(Hilly part !) .. Australia/ Down under !

Re: ATV conversion (mostly done)

Post by Hillhater » Jan 03 2018 5:51pm

Very nice conversion.
I just hope you dont regret using those Headway cells,...they do not have the best of reputations.
This forum owes its existence to Justin of ebikes.ca

User avatar
jonescg   1 GW

1 GW
Posts: 3305
Joined: Aug 07 2009 9:22pm
Location: Perth, Western Australia

Re: ATV conversion (mostly done)

Post by jonescg » Jan 03 2018 11:03pm

Very tidy build!

The Headways will be fine in summer, but they will sag pretty bad in winter.

How far do you think you will get on a charge?

romelec   10 W

10 W
Posts: 90
Joined: Mar 11 2011 3:46pm
Location: Marseille, France

Re: ATV conversion (mostly done)

Post by romelec » Jan 04 2018 4:10am

Thanks !

Yes I expected that for LiFePO4, but it's fine I won't use it a lot and almost never in winter because I will also be cold !

I have no idea for the range but 50km would be nice to have, I expect it to vary a lot depending on the terrain.

User avatar
amberwolf   100 GW

100 GW
Posts: 25132
Joined: Aug 17 2009 6:43am
Location: Phoenix, AZ, USA, Earth, Sol, Local Bubble, Orion Arm, Milky Way, Local Group
Contact:

Re: ATV conversion (mostly done)

Post by amberwolf » Jan 05 2018 1:40am

For winter you could add battery heaters, like the ones used on car-battery lead-acid stuff for more northerly areas. Or those under-tank reptile habitat heaters, like ZooMed makes--they're thin and flat and could be installed inside the battery compartment, then their cords connected together to a single 115vac plug. Leave them plugged in when you're charging, anytime you're not riding but might need to use it, and it'll be warm and ready to go without sag during the ride.

If the battery box is insulated on the outside, it'll keep the heat in, and should last thru it's whole capacity.

User avatar
E-Chopper   10 W

10 W
Posts: 66
Joined: Feb 10 2016 5:39am
Location: Lower Austria
Contact:

Re: ATV conversion (mostly done)

Post by E-Chopper » Jan 05 2018 9:00am

Great Job !!!
nice pictures !!!

Do you want to register it for street legal use or only offroad !?

Greetings from Austria to France
"Thunder is good,Thunder is impressive;
but it is Lightning that does the work !
-Mark Twain

romelec   10 W

10 W
Posts: 90
Joined: Mar 11 2011 3:46pm
Location: Marseille, France

Re: ATV conversion (mostly done)

Post by romelec » Jan 05 2018 12:42pm

I wanted to add a heater, there is some insulation in the box (4mm cork) but I have found these tapes only in USA but the shipping to Europe is pretty expensive, about $50 :?
How much power is needed ?

Unfortunately it is impossible (or very expensive) to register converted vehicles in France, so I will keep it like that.

minimum   10 W

10 W
Posts: 93
Joined: Nov 10 2016 2:53pm

Re: ATV conversion (mostly done)

Post by minimum » Jan 06 2018 2:14am

Look for 3D printer parts stores - some bed heaters for printers are paper thin.
12 VDC version are most common, 24VDC less common and 240VAC are rare. They come with thermistor attached and should have some kind of additional regulation or it will cook your battery.

https://www.robotdigg.com/product/877/2 ... ble-heater

GeriatricGeoffrey   1 mW

1 mW
Posts: 19
Joined: Jan 10 2018 6:04pm

Re: ATV conversion (mostly done)

Post by GeriatricGeoffrey » Jan 10 2018 9:20pm

looks fun!

cost so far?

romelec   10 W

10 W
Posts: 90
Joined: Mar 11 2011 3:46pm
Location: Marseille, France

Re: ATV conversion (mostly done)

Post by romelec » Jun 08 2018 10:36am

Sorry for the very very late answer, it costed about 4000€

It is now almost finished, I still have to tweak the controller to have more power at startup but that's all.
Maybe create different drive profiles as I have a switch wired but is is not really necessary.

The issue I had with the regen not working was because I didn't had a FS1 switch on the throttle, when I added it worked immediately.
For the variable regen I didn't use a brake lever but reused the choke lever used with the left thumb.

I plan to make a video presenting everything but don't know when I will have the time, maybe in July.
Attachments
DSCN3454.JPG
new throttle box made with Curtis pots
DSCN3454.JPG (170.28 KiB) Viewed 1449 times
DSCN3456.JPG
variable regen lever at the bottom
DSCN3456.JPG (174.96 KiB) Viewed 1449 times

GeriatricGeoffrey   1 mW

1 mW
Posts: 19
Joined: Jan 10 2018 6:04pm

Re: ATV conversion (mostly done)

Post by GeriatricGeoffrey » Aug 07 2018 11:42pm

romelec wrote:
Jun 08 2018 10:36am
Sorry for the very very late answer, it costed about 4000€

It is now almost finished, I still have to tweak the controller to have more power at startup but that's all.
Maybe create different drive profiles as I have a switch wired but is is not really necessary.

The issue I had with the regen not working was because I didn't had a FS1 switch on the throttle, when I added it worked immediately.
For the variable regen I didn't use a brake lever but reused the choke lever used with the left thumb.

I plan to make a video presenting everything but don't know when I will have the time, maybe in July.
I appreciate the update!


Looks great, awesome job. I want one :D :D :D

romelec   10 W

10 W
Posts: 90
Joined: Mar 11 2011 3:46pm
Location: Marseille, France

Re: ATV conversion (mostly done)

Post by romelec » Sep 17 2018 9:35am

It is not the presentation video but my first real trip with it (20km with +/- 600m in altitude), still nice I think !


User avatar
Alan B   100 GW

100 GW
Posts: 7486
Joined: Sep 11 2010 7:43am
Location: San Francisco Bay Area, USA
Contact:

Re: ATV conversion (mostly done)

Post by Alan B » Sep 17 2018 11:23am

Nice! Would be quiet and fun.

I have a 2wd ATV that I have thought about adding an electric "Stealth Mode" to. Keep the gas engine for range, but add a small electric system to run silent and slow for short distances. :)

User avatar
fechter   100 GW

100 GW
Posts: 12913
Joined: Dec 31 2006 3:23pm
Location: California Bay Area, USA

Re: ATV conversion (mostly done)

Post by fechter » Sep 17 2018 2:17pm

romelec wrote:
Sep 17 2018 9:35am
It is not the presentation video but my first real trip with it (20km with +/- 600m in altitude), still nice I think !

That thing is going pretty fast up the hill. Very impressive. 600m climb is good performance too.

One fun thing about electric rides is you can sneak up on wildlife. In my area there are lots of deer and coyotes. You would never see them with a gas powered ride.
"One test is worth a thousand opinions"

User avatar
Alan B   100 GW

100 GW
Posts: 7486
Joined: Sep 11 2010 7:43am
Location: San Francisco Bay Area, USA
Contact:

Re: ATV conversion (mostly done)

Post by Alan B » Sep 17 2018 5:42pm

Idling along slowly with the ATV doesn't seem to bother wildlife much, usually. At least with my ATV the exhaust is quiet and in the rear. The noise comes from the low pressure tires popping little rocks or crunching leaves on the ground, but that is pretty quiet too, depending on the leaves or whatever is underfoot. Wildlife often doesn't spook until you stop, or especially if you step away from the ATV. As long as you stay on it they seem to be, for the most part, unworried. However if it was quieter it might be even better. :)

romelec   10 W

10 W
Posts: 90
Joined: Mar 11 2011 3:46pm
Location: Marseille, France

Re: ATV conversion (mostly done)

Post by romelec » Sep 25 2018 9:00am

No idea about wildlife, there isn't much around here (or I don't see them), but the MTB riders/hikers appreciate it !

The power above 10km/h is great but not under, it is difficult or even sometimes impossible to start uphill, I don't know why.
There must be some parameters to change but which ?

Post Reply