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Old 02-06-2012, 10:10 PM   #18 (permalink)
TomEV
Ford Escort 2.0
 
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Join Date: Feb 2008
Location: Alameda, CA
Posts: 240

Electricar - '89 Ford Escort LX Hatchback
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The GE 3.5 and 6 HP motors are virtually the same electrically - Same field shoes, same brushes, same armature windings. Main difference is the armature shaft is male on the 3.5, and female on the 6. (there are a couple of other structural differences so they mate properly with the Terrell or Dana axle).

They have different ratings because the 3.5 is a 'closed' motor (no ventilation) while the 6HP has a cooling fan.

The high speed is mostly limited by the amount of RPM you can attain before counter EMF forces self-limit the motor RPM. 35 to 37 MPH is what I would expect in a stock Comutacar/Dana axle, and about 32 - 34 in a Citicar/Terrell axle. Ways to decrease counter EMF force is to use field weakening (weakened counter EMF, allowing the motor to turn faster at the top end) and/or increasing the voltage. Going to a higher amperage controller only affects low speed acceleration, as these motors can only use over 400 amps up to about 1,000 RPM.

You'd probably only notice the difference in speed and acceleration if you broke out the stop watch and timed a 48v Citicar and a Comutacar zero to top speed. Do you have any 'virtual drag race' numbers for your Comutacar? With the Comutacars I've driven, (sample of two) I found them to be somewhat slower to accelerate - but very much quieter. My 'silent' EV is anything but! I am very jealous of the Dana axle... Imagine a '30's pickup in granny low - and then put that gearbox sound in a plastic car, going 35 MPH.

Replacing the transaxle was one reason why I got a basket case Comutacar - unfortunately, someone had modified the transaxle with 12:1 ring and pinion - not terribly useful. I donated the Comutacar to the local high school for a project/instructables car as it didn't have any of the body panels, and was missing too many parts to make it into a road worthy vehicle.
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