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Old 01-11-2017, 10:22 AM   #71 (permalink)
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Join Date: Dec 2016
Location: Romania
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Simba - '05 Seat Leon FR
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Took out the dead battery. As I've suspected, it was frozen. As in covered with frozen leaked out electrolyte. 5.64 volts at terminals. Dead as a dinosaur.

Acquired a "virgin" (dry-stored, filled upon purchase) AGM motorcycle battery of 12Ah from Varta. Compared to the defunct 10Ah is a bit heavier (~4kg weight) and potent enough for a 1.8 liter engine by itself, as factory recommended for 1800cc Suzuki Intruder. Got it thoroughly tested and warranty covered as an automotive-systems auxiliary battery, to avoid future hassle. Once filled up, left to settle and charged to specs it holds 13.02 volts.

This should bring the fully assembled hybrid to 6kg in weight. Cutting corners (literally ) means little advantage.



Once fitted, it may bring some minor advantage in mileage, as the supercaps charge very quickly and there is little work to do by the alternator. (Alternators are miserably inefficient, about 40% over most of the rpm band, so they draw pretty kilowatts from the engine while under electrical load.) This is not its purpose, the goal is removal of weight from outside the wheelbase.

Removed the balacing circuit boards and tested the supercaps again. They charge much quicker with a battery charger, hit about 14.25 volts, charger LED lights up and they don't seem to get more charge. Left them to settle down. Dropped to about 14.08 volts and individual voltages in the string are:

+ 2.40 2.27 2.29 2.43 2.21 2.48 -

Charged again to ~14.8 volts and tested the individual voltages in the string. Highest voltage cap closest to - terminal, 2.58 V, lowest 2.38 V (2 caps), the rest in the 2.4x range.

The ratios between individual voltages are similar to what I've got before, with balancing boards fitted. Proof the boards did nothing useful.


Last edited by Nautilus; 01-16-2017 at 03:26 AM..
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Old Today, 02:00 PM   #72 (permalink)
EcoModding Lurker
 
Join Date: Dec 2016
Location: Romania
Posts: 8

Simba - '05 Seat Leon FR
Thanks: 13
Thanked 6 Times in 4 Posts
120 kms (75 miles) of road tests with new capacitor-battery combo (Varta 12Ah AGM, thicker copper strips between supercaps, no balancing boards) over 2 days and 2 nights.

Temperatures: -2 to 5C (28-41F) day, -6 to -7C (19-21F) night.

Voltage: 13-13.1 volts just after full charge. Drops to ~12.83 volts after 24 hours. Stays at ~12.6-12.8 volts through the day, multiple starts and drives.

Alternator voltage: 14.6-14.8 volts engine cold just after start. 14.3-14.4 volts engine warm, headlights off. 14.0-14.1 volts engine hot, headlights on, after hours of driving.

Start: 1-2 seconds of cranking. Voltage drops very briefly below 9 volts during cranking.

Rpms climb a little bit faster. Smoother running under load and high rpm.

Effects on roadholding: sharper turn-in on corner entrance, enough to trigger the ESP on dry tarmac with summer tires. (This is due to all bits and pieces moved to change the weight distribution, 36-42 kg overall, not just lighter battery.) Slightly smoother acceleration in gear.

Can be charged by the solar panels over the trunk lid.


Last edited by Nautilus; Today at 02:22 PM..
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