specs for D&D

This is a list of the information that D&D would like for them to recommend a motor. It is probably a worthwhile exercise to figure this stuff out anyway. I will gradually fill it in.

Vehicle Information

*Vehicle Type(brand) :

Mazda 121

No Load Vehicle Weight :

I think about 900kg standard (need to check)
seems like I might pull out about 100kg of stuff and add about 2-300kg of stuff

I need to check how much extra weight (batteries etc) I will actually have.

1100kg (conservative)

Full Load Vehicle Weight :

at most another 300kg (four people + some other stuff)
1400kg (conservative)

Drive Wheel Diameter :

13 inch (need to check)

Rolling Tire Radius :

What differential / transmission does (or will) the vehicle have?
And/Or describe the mechanical design.

FWD manual transaxle - B5M-R

Differential / Transmission & Axle Ratio :

1st - 3.454
2nd - 1.944
3rd - 1.392
4th - 1.030
5th - 0.810
Reverse - 4.058

Final Drive Ratio - 4.058

Differential / Transmission & Axle Efficiency :

* Max. Vehicle No Load Speed (on level ground):

70km/hr

* Max. Vehicle Full Load Speed (on level ground):

60km/hr

Minimum Vehicle Full Speed up % Grade

*Controller Make and Model :

sevcon powerpak (user manual)

Motor Requirements

H.P. :

15-20?

RPM :

Max depends on final transmission ratio

Max AMPS :

425 - based on planned controller

*VOLTS :

80 - based on controller

Duty Cycle Requirements :

*Quantity of Motors Per Year :

1

Comments :

Wish to see if sepex is possible

Send Vehicle Photo ( .jpg, .gif, .tif, .png) :

regen with series DC

I am at the stage that the only benefit of sepex over series DC seems to be regen abilitiy.

If I can be satisfied that regen is okay with series then I think that I will go that way as that is a much more standard way to go with components easier to find.

This seems to be pretty conclusive...

"In particular you cannot get regenerative braking with a series wound motor."

[ http://www.4qd.co.uk/faq/bmnc3.html#motch ]

seems that I should also keep the clutch

At least to start with, it seems like a good idea to keep the clutch

I know that I should know this already but here is the clutch explanation

http://auto.howstuffworks.com/clutch1.htm

Seems that I would need to make a flywheel that bolted onto the motor shaft and a stationary plate to bolt to the bell housing equivalent.

although all these kits use clutchless connections

http://e-volks.com/electric_car_conversions.html


these conversions use a clutch

http://www.electroauto.com/catalog/adaptors.shtml

but are very expensive - easier without a clutch?

here is a good comparison...

http://civic-ev.blogspot.com/2008/05/ordering-motor-adapter.html

which is a summary of

http://groups.google.com/group/civic-ev-kit/browse_thread/thread/4e5acb932c92f43f


seems to be about $875 us for the adapter plate kit

http://www.electroauto.com/catalog/price-pts.shtml


here is a good place to start

http://www.evconvert.com/article/your-first-electric-car

come back to that later - now I need to sort out mechatronics urgently


Here is a good diagram from d&d motor systems showing what is needed.


I think where I am at is to use the gearbox and a clutch with a d&d sepex motor and sevcon powerpack controller (72V system)

http://www.thunderstruck-ev.com/ddmotor.htm

I have no idea what sort of d&d motor this is though - that will decide if it is a goer!!

although it seems that it is going to be a bit marginal with power :-(

only real advantage of sepex now is regen!

maybe the gearbox is a good thing!!!

this seems a pretty good argument for keeping the gearbox

http://www.cafeelectricpress.com/blog/?p=22

Although the factory evs all seem to have no gearboxes.

current thinking....

keep the gearbox and put in sepex for regen.

obviously heaps more thought required.

Hopefully the 121 manual that I ordered last night will help out!!

If I am to have a front diff

http://www.proev.com/P1Diffs.htm


http://books.google.com.au/books?id=bQFuTCGNYWgC&pg=PA229&lpg=PA229&dq=ev+++fwd+differential&source=web&ots=HAlD5EBl5h&sig=oho6RZgYS0MqxWDhWJFUqzBnlXo&hl=en&sa=X&oi=book_result&resnum=9&ct=result

Will two motors really work?

Rationale.

I am keen to use sepex and it seems that that smaller 8hp sep ex motors running at 36v are much easier to come by than higher power units. If I have to use two of these to get the power, then it would seem to make sense to drive each front wheel from a motor (maybe I need a timing belt reductioBlogger: elowly - Create Postn to get correct speed).

Do I need two controllers? How do I syncronise them? If I have one controller, can I just connect the motors in series? Can I find a 72V sepex controller?

Otherwise, can I just use a front diff and a larger sepex - as in

http://www.electricmotorsport.com/store/ems_ev_parts_motors_sepex.php

here is a link with some comments on dual motors
http://www.mail-archive.com/ev@listproc.sjsu.edu/msg05516.html

sepex controller possibilities

do they have regen, CAN connection?

I thought that I needed this "multimode thing that curtis has but I am not so sure. If you can set one "throttle response" curve, that may be all I need.

Curtis

http://www.alltraxinc.com/files/Doc120-017-C_OP-Controller-Pro.pdf

curtis seems the best but I cannot find anyone that sells them. This seems the only one that can be configured for different "modes" that seems vital to utilise the benefits of sepex. If I am correct, these modes should be able to be used as gears (I am not so sure now).

Alltrax

ev motorsport have two possible controllers, alltrax and sevcon. Alltrax seem to be the lower power ones.

http://www.electricmotorsport.com/store/ems_ev_parts_motors_sepex.php

here is the manual for the configuration - seems you cannot use different "modes" as you can in curtis versions

http://www.alltraxinc.com/files/Doc120-017-C_OP-Controller-Pro.pdf

Sevcon

These guys seem to have the most power, but no modes. I am not sure that I need quite this much power if I am planning to use two motors.

http://www.sevcon.com/pages/powerpakSEM.html

Kelly

kelly seems to have regen but no "modes"

$289 in the shop: http://www.kellycontroller.com/shop/?mod=product&cat_id=27,4&product_id=128

here is the operating manual:

http://www.kellycontroller.com/mot/KellyKDUserManual.pdf