Kadet E GT EV Conversion

[MPaulHolmes]

I'm just waiting on the mosfets! I can't wait to read more progress from you!!! Ya!

[jerpelea]

update

just got the response from battery seller

we will use 10 FIAMM 12SLA75 (Calcium Batteryes) for main pack

Nomina Voltage = 12 V
Nominal Capacity (10 Hours) = 75 A
Shortcut Current = 3000 A
Internal Resistance = 4Mohm
Dimensions LxWxH =360x164x228 mm
Weight = 29kg

total weight 290Kg for main battery pack

we will use 1 FIAMM 12SLA50 (Calcium Batteryes) for 12V DC
(to be checked if is better to use dc-dc converter 120-12V )
(how it influences the overal performance adding 21kg for 1 battery or use main power also for electronix)

Nomina Voltage = 12 V
Nominal Capacity (10 Hours) = 50 A
Shortcut Current = 2030 A
Internal Resistance = 6Mohm
Dimensions LxWxH =288x173x202 mm
Weight = 21kg

[jerpelea]

Update


the car has new rims on it
and also work on the body has started
there is no more rust

next week i hope to get all leds to finish the lamps

[MPaulHolmes]

Awesome work! That's what I call a work space. Man! Not fair! That car is going to be perfect for a conversion.

[jerpelea]

update on electronics design to lighten the car and lower the costs !

solar pannels are (180W on top of the car and 60W on the hood installed power)
due to limited car space for solar power, total is 240W/h so best charge will be 240wx8h=1920W / day

to benefit from all this energy we need to charge both packs 144v and 12v and loose lot of power on voltage conversion
pannels have 36v so an down conversion to 12v and an up conversion to 144v
the design will be complex and we thought for something else

an single pack for propulsion and electronics so car will use single battery pack for propulsion and electronix

so the new plan

an computer power supply can convert 90-240v ac to 12V/20-50A dc depending on model so we can use an computer power supply if we modify it for dc imput (remove primary ac-dc block) and create better cooling removing the case/fan and create an new case from big aluminium radiators
Also computer power supply has an conversion rate of 85-92% wich means that is better than any home built power converter
Also 30A is enough for powering the lights
70W = 2x35W HID Lamps for headlights
5W = all signal and position lights
5W = all internal lights
20W = controler board
20W = radio device
90W = Heater (very important)
40W = computer and gps (Asus Eeepc 7" converted as dash computer)
total for now 160W so less than an 400W power supply

the second improvement
usind only one battery pack we need only one converter from 36v dc solar pack to 144v dc (solar pannel has 240W so an commercial 12v dc to 110/220 ac 300W is enough)
this type of converter is used to power house electronix from an car battery in car and we need to add an ad/dc converter on the output and charge the car battery
also using this the variable 24-36v loar pannel output is converted to stable 12v and from there to 144 from this convertor

so 2 power issues are solved in theory
i will come with design updates and pictures soon !!

[jerpelea]

update

to test my power theory
i have ordered an
500W 12 to 110v convertor for solar pnel
500W 110v to 12v convertor for electronix

also LEDS are here and first backlight is ready clean and nice 150mA with all lights lit


i need some sleep

[jerpelea]

both backlights are ready
tomorrow some pictures and maybe if i have time an move with all backlight functions


rear light 1 piece
12 LED - rear light
12 LED - rear light signal
16 LED - position and brake
12 Diodes 1N4007 to reduce voltage on position circuit in series with LED to dim LEDS on position lights (0.6vx12 diodes=7.2v)

also 1 test board for rear lights
price 25 USD/light block

total price 50 USD

[Daox]

Nice job on the tail lights.

[jerpelea]

update

i got front lights :d

old front lights
H4 55W+60W
i have measured the current
for 1 bulb is
short light (60W powered)4A
long light (60W+55W powered)=4A+3A total 7A (84W)
so the indication on the bulb is not right
but is too much for an electrical powered vehicle


i got an set of BMW HID lights (pictures atached) with rated power 35W
so i will need to find H4 hid bulbs and i am ready
measured current for 1 lamp 2.2 A (39W)
this hid is used for both short and long lights so total used power per side is 39W


also rear ligts are ready and current is measured

for 1 tail light
0.03A (0.36W) = position
0.17A (2.04W) = brake
0.13A (1.56A) = rear light
0.13A (1.56A) = reverse

those values are final
llights are tewaked for optimum contrast

[jerpelea]

finaly

power supply 100-240v/12V-34A(2x17) 85% randament has arrived

silverston SS430GB pc power supply
it can handle
input 110v-240v range (144v is in range) 7A top
this pc power supply is rated 82+ at 110V

from my test i have 85% conversion at 144V
for 100W drain i get 85W output

features output dual 12v 17A rails from independent outputs
17A for elecronics
17A for lights
i think that is enough for all i have

maximum power on 12v is 360W
power supply is protected to overcurrent shortcut and has thermal shutdown

for dc imput i need ti remove first AC-DC block and the converteri s ready

i need to make new sealed case 150x100x100mm from aluminium blocks wich is enough to remove the fan and cool the power supply

mods
i have removed all useless dc lines 3.3V, -12V and 5V
i have added an swich to power the supply (soft start)

pictures of modded power supply are atached
last picture is an closeup for the ac-dc block
you need to remove it and plug the battery in place of his marked "+"."-" terminals

!BEWARE OF POLARITY