Research for a 1:1 electric car

[lincpimp]

I like the idea of some used/surplus parts... I will have to look into finding some used motors, and possibly controllers. Wonder if the forklift parts would work? I am guessing that they run on lower voltage that I plan to use.

[sikeston34m]

Originally Posted by lincpimp

I like the idea of some used/surplus parts... I will have to look into finding some used motors, and possibly controllers. Wonder if the forklift parts would work? I am guessing that they run on lower voltage that I plan to use.

What voltage do you plan to use?

I think I have a couple of 350 amp brushed controllers that are 24 volt.

They are made by Curtis Instruments. If you're interested, I can get you the model number and the spec sheet.

[Metallover]

That DIY electric car forum is boss!

I just was going to point you to a forklift motor sticky - http://www.diyelectriccar.com/forums...good-7598.html

Jesus! Someone is putting a 200kw 700v ac induction motor in a brand new BMW! I wish I had the money! http://www.evdrive.com/BMW_project/ACmotor.html#Oct08

[JERRY2KONE]

Originally Posted by Metallover

That DIY electric car forum is boss!

I just was going to point you to a forklift motor sticky - http://www.diyelectriccar.com/forums...good-7598.html

Jesus! Someone is putting a 200kw 700v ac induction motor in a brand new BMW! I wish I had the money! http://www.evdrive.com/BMW_project/ACmotor.html#Oct08

I printed out that BMW project to do some deep reading. This thing looks very interesting for sure. I have not seen any mention of how much it all cost him though?? The project looked very clean and top notch for components used. If the price was reasonable it sould be well worth doing just to get rid of gasoline costs. From everything I read he really did his homework and got his setup dialed in. I would like to see some specs on testing to see just how well it works. At any rate with linc having a nice shop and time on his hands it should be a very doable project for him. Good luck with that pimp.

[MTBikerTim]

That BMW project looks awesome. Can't wait to see that completed.

[Metallover]

On the BMW project I don't think the motor or the controller is made anymroe. You know what, the motor is made but very hard to get and from what it sounds like the only controller that works with it isn't made anymore.

Before anyone attemps a project like this make sure to do LOTS of research. I'm just doing an electric bike and I feel almost in over my head.

[lincpimp]

Ok, time to bounce some ideas off you guys! I have started a thread over on DIY, but I figured I would get some input here.

Seems like my best be is to get a small vehicle with a manual tranny. Use the clutch and tranny with a premade motor adapter, and use a forklift motor. I have asked over at DIY for a link to cheapest adapter available, cause that part alone can be a grand...

No I am guessing that a large DC motor controller is very similar to a brushed motor esc... I am almost thinking that I could make my own mech unit... Maybe I will not get that ambitious, but it must be pretty simple.

Any ideas or thoughts...

[Metallover]

Make sure a forklift motor is your best option. There might be better ones out there... BUT if you can get a used motor that would cut the motor price in half.

Are you saying you could build your own controller? That's be sweet!

[JERRY2KONE]

Forklift motors are quite powerful and have a proven track record for performance and durability. I think it should work great if you get it geared correctly. I would think that the best way to come up with and adapter plate for the motor/tranny connection will be by making your own custom plate. Just by taking the motor mounting plate and the tranny mounting measurements and combining the two into one plate. If you do the drawings privately you should be able to get a CNC shop to cut it for you within a reasonable price range like a couple hundred $$$. I would be willing to bet that there are a few guys in here who would love to help with CAD work in order to get what you need for the CNC shop. Just acquiring the motor, tranny, and getting them mated together will be a huge milestone for your project. that should be the easy part. Actually getting the controller and system to work properly will be the real challenge I would think. This will more than likely be your toughest project yet James. Not like tinkering with a little R/C toy that is for sure. Have fun.

[lincpimp]

The mech parts will be the most difficult and time consuming part. I found a "how to" dvd about adapter making for 10 bucks, I will most likely buy it and see if it helps...

I have plenty of mech skill, built a few engines, trannys, axles, etc. The wiring and electrical parts should be easy. Everything I need is just plug and play... Almost ruins the fun!!! I will have my own "touches" on this conversion, that is for sure!

[bigboi146]

Make sure you post billions of pics.

[lincpimp]

Originally Posted by bigboi146

Make sure you post billions of pics.

Will do... Just need to do tons of research first!

[JERRY2KONE]

Originally Posted by lincpimp

Will do... Just need to do tons of research first!

I must say that I will be looking forward to seeing your completion post in a year or so, and that is if things go well. Still this is going to be one of those very cool reads that others will want to do on their own DIY. I sure hope your up for this one James. Nothing will be easy, but we know there are a lot oftalented people in here that can help with setup, diagnostics, theroy and whatever else one may need.

[sikeston34m]

Just remember, Electric Horsepower is MUCH different than IC Horsepower.

For example, a 10,000 pound forklift carries around a 3000lb load with a top speed of 8mph. This uses a 6.6kw drive motor drawing energy from a 36 volt 1000ah lead acid battery. The Battery weighs 2850lb and gives 5 to 6 hours of runtime, sometimes more, sometimes less depending on use.

6.6kw or 6600 watts is only 8.85 horsepower.

There are Brushed DC versions AND also Brushless AC versions. The AC versions do have regerative breaking.

The AC versions do use sensors in the form of an encoder bearing. The upper bearing has a ring in it that rotates with the armature shaft. What appears to be 3 small magnets rotate on this, placed specifically at the point of phase shift. A hall sensor alerts the traction amp to armature position.

I've seen a few encoders go bad after about 12,000 hours of use. It's not a pretty sight to see a motor this size cog.

A Brushed setup would be cheaper to setup. But the Brushless version has advantages over the Brushed setup.

The AC (Brushless) motors are NOT a permanent magnet motor. They are strictly iron core stator motors.

Just remember, as you're checking out these high performance elaborate setups, it doesn't require 300 electric horsepower to accelerate REALLY hard.

Efficiency is everything if you want extended range and battery cycle life.

From my experience with working on electric forklifts, I can see most of the automotive conversion. The only debate in my mind is how to control the speed controller.

Control as far as I know, has to be done with a potientiometer or pwm.

A spring loaded pot, that when released returns to neutral, is what is used on the forklifts. This pot, returns positive signal voltage on the forward side, returns negative voltage on the reverse side.

As you press harder on the throttle, the voltage return increases and so does acceleration.

Neutral, of course, returns no voltage.

Where are you in your research? Talk to me here. LOL I'll help you anyway I can.

[lutach]

Research is your best friend and I've been at it for over 8yrs now. Some parts are cheap and some are very expensive. Cost will depend on what performance you want.