DIY Volt Hybrid - Open ReVolt style

[todayican]

Very, VERY cool Ben!

[todayican]

I just had an idea, that leads to a question...

On my trike build, I'm thinking, why not build it as series AND parallel, use the diesel to turn the drive motor via a centrifigual clutch and a second sprocket on the drive e motor and use a smaller generator to pump excess amps back into the pack.

So heres the question: If Im using a dc gen and modulating the diesels some (as a parallel, there would need to be some fluctuation going up and down hills, varying speeds etc.

If I calculate the gens output to not exceed a certain voltage, to not over volt the batteries, possibly even "cap" the voltage somehow (not sure how to do this) what happens if im sending volts and amps into the batteries thats too low? so for example, if im sending 70v x 20a into the pack that is sitting at 80v I understand it wouldn't charge, but would it harm the batts?

I guess another question would be how could I "stabilize" the gens dc output?

[bennelson]

Making some as serial/parallel hybrid makes things complicated real fast.

The Prius' transmission is absolutely magic how it works. The Volt transmission is very similar to the Prius, but changes what parts are hooked up where.

For a home-brew solution, something more like the Honda IMA system makes more sense, but I sure don't have room for all that under the hood.

A serial hybrid makes things REAL SIMPLE. In my case, splitting the hydrocarbon combustion system from the electric drive system allows everything to fit in the car AND it's somewhat modular - the "Hybrid" part could be on a trailer, a removable hitch, or built into the car.

[todayican]

The way im thinking, since its on a single wheel drive trike, is the gen and diesel would be a 10 min job to put in or take out. (Diesel site directly above gen and drive motor anyway) so the 2 chains would line up.

I have a post in over at endless sphere to see if an ebike controller could do the job of stabilizing the voltage coming from the gen.

Its a lot of pasting stuff together, but Man, is it fun! lol

[bennelson]

I got to work on the project for a few more hours today.

My buddy Steve stopped over to give me a hand. We zip-tied up the 12V+ ignition cable under the car.

Most of what we were doing was trying to figure what goes where, and how to fit it all in there.

We decided on
Propane tank on far left.
Circuit breaker, outlet, and starter relay right behind it.
Generator in the middle, with exhaust below.
Demand regulator on the right.
Charger on the right, behind and above the regulator.

Everything fits in the cargo compartment this way.



I cut some plywood to fit inside the bedframe generator rack. It's sized to fit inside the frame, and has a couple of self-tapping screws through the wood, into the frame.

I already had the breaker box and outlet on a piece of plywood, so we just mounted that vertically, leaving enough room for the propane tank. The starter relay and ground screw was also mounted just below the breaker box.

Here's a reverse angle photo:

Since the outlet faces the front, it makes it easy for me to put in a Kill-a-watt right there for testing purposes.

As for the charger, it's NOT working right now. I plug it in, it powers, it just doesn't charge. It acts exactly as though the pack is fully charged.

I just got an email back from somebody else who has the same charger. I asked him to open his up to check on that resistor. Turns out I put one of the wrong value in. The value is off by about 25%. I wonder if I can trick it by simply adding an intentionally wrong "programming resistor" where you set the system voltage in the charger. Hmmm... That might actually work....

Also, I had a fun experience getting gas this morning (for my pickup truck for a long trip.) This sign was at the pump.


Oh well, just one more reason to go gas-free!

[bennelson]

Yesterday and today were kinda the big push to get this project done.

And guess what, it is!

I still have a few modifications to do, but the whole thing works!

So, of course, I did have to change the graphic on the rear of the car.



See, nothing tape and a marker can't fix!

[todayican]

More data, More data! and a video :-)

[bennelson]

It's coming.

Look for a couple videos this evening.

-Ben

[bennelson]

Here's a video for you.

This one explains how I remotely control the generator.
Since the Electro-Metro no longer has an engine and starter in front, no reason not to use the key crank position!

Hmmmm. I wonder... Anyone else have a REAR-ENGINE Geo Metro?

http://www.youtube.com/watch?v=Qc-7mK8-hvE

[todayican]

Nice! (And I say that word, the EXACT same way I used to when I was admiring someones 6pac fire breathin challenger (Man, I AM getting old...) lol