Electric Assist Project: E-charger (2000 Subaru Outback) - Page 4 - Fuel Economy, Hypermiling, EcoModding News and Forum

Phantom · 07-23-2010, 02:36 PM

Since you will be using the motor to assist it would probably work best to have the controller base the output on Load and RPM. That way if cruising at 60mph on flat ground then you hit a hill and the load normally would go up say 40% the controller sees the increase in load and increases the output of the assist motor reducing the overall load on the motor making it easier to stay at speed with out adding throttle.

brucey · 07-23-2010, 05:14 PM

That's the plan! Except it's going to be much simpler than that:

I'm simply going to have 2 independent throttles. I'll control the electric motor with my hand and the regular gas engine with my foot.

brucey · 07-26-2010, 05:02 PM

72Volt system is what I'm going for now, after talking to the motor people. I might change for a smaller battery to make mounting them easier.

Anywho, had a few minutes extra today and decided to mock up the motor.

I apologize for the crappy mock up, but look it has the motor written on it!

Anywho, it looks like it will fit with some work. I'm going to have to move the power steering reservoir for sure. It seems on some subaru's it's located on top of the steering pump.

Which is what I'll be going for. Hopefully I can fit the stock one in place, if not I guess I'll have to go to the junkyard and find one that fits.

The ABS Pump/lines seems to be less of a problem. I might need to move it, I might not. Depending on how big the bracketing is for the motor. If I do have to move it, the plan is to simply copy what others have done and shove the pump into the fender:

Man is it a nice day to be working on a piece of lego.

Anywho, the engine redline is 6000 RPM, and the motor is 7500 RPM. Which means I need a 12:15 or 1:1.25 ratio?

Dr. Jerryrigger · 07-27-2010, 02:12 AM

they changed around the power steering between 99 and 00. I think they would be easy to swap, but the newer ones turn off as you go faster, so you might just want to try and relocate the holding tank, or if you don't mined driving with out PS for a few days I'll Fed Ex you mine in trade for yours.

brucey · 07-28-2010, 04:35 AM

Thanks Doc, I'll take that into consideration if I can't find something. Although I also have my girls forester which has that style reservoir, which I might just trade with her if she says it's alright. Looks dead simple to move anyway it goes.

I also found info tonight about the GM B.A.S. Hybrid which is basically a really big alternator that can start the motor/regen. Well that's a lot of confidence with me knowing the belt should be able to handle the power! And hey, if my starter goes I'll have a redundant one wouldn't I? I could just spin the motor up with the AC-12.

In fact, I think I'll have a lot of redundant things on the car with this system in place. I could undoubtedly run a 12V converter in place of the starting battery, the alternator would also be mostly useless. Along with the starter too. Oh well, that's stuff to worry about once the system is operational right?

ShadeTreeMech · 07-28-2010, 02:34 PM

The nice thing about a redundancy is something being a bit more fail safe. And i suspect the car would be "happier" with its OEM alterator in place.

just my .02.

Phantom · 07-28-2010, 03:54 PM

Brucey do you have any other info on the B.A.S system I'm wondering how exactly that did it as they have the same car with out it and and option with it. If I find anything use full I will let you know.

brucey · 07-29-2010, 01:18 PM

Geneva '08: GM announces new second-generation mild hybrid system — Autoblog Green

That's the best explanation I've seen. Looks very very simple and easily adapted to any car.

brucey · 07-31-2010, 04:08 PM

Ok, so had about an hour to fiddle with my engine bay today. I looked into relocating the power steering reservoir and can't find an easy location. I'm considering simply pushing it all the way back of the engine bay, near the air filter box.

I'm also considering swapping out mine with my girlfriends forester, since we both have the EJ25 SOHC, it should bolt up. This would be less ghetto but a lot more time intensive.

brucey · 08-04-2010, 04:42 AM

OK, so my original ideas of using T105 batteries might be questioned.

I really would like the entire battery pack fit into the area shown earlier in this thread, as to keep the usefulness of the trunk still. But fitting 12 of the T105's into the car might be a bit of a hassle. I still would like to go for lead, since it's cheap. And eventually switch up to lithium of some sort.

Any ideas of from anyone for a battery that can handle 400Amps regularly? I'll be calling my local golf cart guy tomorrow.

I also looked into the bracket itself. I found a design that would suit both the cars engine, and the electric motor.

It attaches on the front of the motor via the Power steering pump bolts and a secondary bracket attached to the intake manifold. I might add a few extra braces on mine though.

Then dug up some diagrams of a smaller bracket for a different set up:

2000 Subaru Impreza 2.5RSC Build Diagrams - Ludicrous-Speed

and used the dimensions given between the bolt holes on SC5 as a measurement, and got these rough dimensions:

And started digging in the scrap pile.

As it happened, I have a 10" by 15" piece of 1/4 6061 aluminum. So I think the first bracket should be starting to come together soon. I really would prefer steel for this, but we'll see if this is good enough. I also can't finish the motor until the bracket arrives, for final fitment. Then it's just a matter of finding the pulleys and tighten'er down!

PS: All information is found via google and owns to their owners. GG