ATV conversion (mostly done)

Electric cars, trucks, ATVs, NEVs - things bigger than a motorcycle.
Post Reply
romelec
10 W
10 W
Posts: 94
Joined: Mar 11, 2011 3:46 pm
Location: Marseille, France

ATV conversion (mostly done)

Post by romelec » Jan 03, 2018 11:42 am

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 317 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 317 times
_DSCN3413.JPG
_DSCN3413.JPG (113.8 KiB) Viewed 317 times


BMS: the last model from foundingpower bought before they stopped
_P1050834.jpg
_P1050834.jpg (111.04 KiB) Viewed 317 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 317 times
Everything fits very very tightly:
_DSCN3416.JPG
_DSCN3416.JPG (117.95 KiB) Viewed 317 times
_DSCN3417.JPG
_DSCN3417.JPG (107.25 KiB) Viewed 317 times

romelec
10 W
10 W
Posts: 94
Joined: Mar 11, 2011 3:46 pm
Location: Marseille, France

Re: ATV conversion (mostly done)

Post by romelec » Jan 03, 2018 11:48 am

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
1 MW
1 MW
Posts: 1888
Joined: Jun 15, 2009 10:58 pm
Location: MA
Contact:

Re: ATV conversion (mostly done)

Post by skeetab5780 » Jan 03, 2018 12:38 pm

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: 12006
Joined: Dec 31, 2006 3:23 pm
Location: California Bay Area, USA

Re: ATV conversion (mostly done)

Post by fechter » Jan 03, 2018 2:27 pm

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

Hillhater
100 GW
100 GW
Posts: 8406
Joined: Aug 03, 2010 10:33 pm
Location: Sydney ..(Hilly part !) .. Australia/ Down under !

Re: ATV conversion (mostly done)

Post by Hillhater » Jan 03, 2018 5:51 pm

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: 3385
Joined: Aug 07, 2009 9:22 pm
Location: Perth, Western Australia

Re: ATV conversion (mostly done)

Post by jonescg » Jan 03, 2018 11:03 pm

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: 94
Joined: Mar 11, 2011 3:46 pm
Location: Marseille, France

Re: ATV conversion (mostly done)

Post by romelec » Jan 04, 2018 4:10 am

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: 24228
Joined: Aug 17, 2009 6:43 am
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 1:40 am

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
1 W
1 W
Posts: 64
Joined: Feb 10, 2016 5:39 am
Location: Lower Austria
Contact:

Re: ATV conversion (mostly done)

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

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: 94
Joined: Mar 11, 2011 3:46 pm
Location: Marseille, France

Re: ATV conversion (mostly done)

Post by romelec » Jan 05, 2018 12:42 pm

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
1 W
1 W
Posts: 56
Joined: Nov 10, 2016 2:53 pm

Re: ATV conversion (mostly done)

Post by minimum » Jan 06, 2018 2:14 am

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
100 µW
100 µW
Posts: 7
Joined: Jan 10, 2018 6:04 pm

Re: ATV conversion (mostly done)

Post by GeriatricGeoffrey » Jan 10, 2018 9:20 pm

looks fun!

cost so far?

Post Reply