Kadet E GT EV Conversion
 

Hy all

i just bought this "beast"

960 kg / 115hp / and an echonomical 20l/100km

hope to become an nice ev :thumbup:


planned components

drive:
motor warp 9"
paul's 500A controller
10 GEL forklift batteries

chargers
DIY charger
solar pannels
small 2 kw generator (petrol) for extended range or fast charge

Attachment 4525Attachment 4526Attachment 4527

Hey look its already a EV it has a battery charger hooked to it... :D

Kidding. Keep the info coming...

Dave

update

the car is at the boday shop for repairs

in the meantime
we have ordered the comtroller (thanks Paul)
and the motor (thanks Netgain)

we have started the gas peddal conversion (pictures will follow)
gas pedal is based on clasic design with cable and an 5k variator


for batteries we plan to use 10 calcium batteries (around 100 EURO)
SLA 75 wich will give is around 100km authonomy
found compatible chargers for 144v list atached (can be used as guide for our charger)
different batteries and chargers brochure atached including cheap calclium batteries
Hotfile.com: One click file hosting

found digital scope and pannelmetters for replacing old metters on car
those fit perfect replacing old ones
atached also here / maybe are usefull for others
Hotfile.com: One click file hosting

secondary solar charger ....
secondary gas generator ....
to be checked for performance

progress

DONE
signal lamps are now leds

original lamp was using 25w lamps
led lamps use 7 12v leds 0.6W all (0.047A measured for the 7 leds)
price 10USD / Lamp

TODO
building signaling circiut because old relay will not work due to low current


UPDATE

i have found and ordered 100x150 cm of fotovoltaic cells for roof
200 USD for all
will see the test for performance
from diagram each cell is 36v/7A


rear lapmps conversion
will follow shortly
Attachment 4726Attachment 4727Attachment 4728Attachment 4729
Attachment 4730Attachment 4731Attachment 4732Attachment 4733

work started to rear lights

but unforunately stoped for 1 week

i need more leds :(
for now only rear light is working
calculated cost 30 USD/lamp block

tests
rear light 100 mA (0.1A)
original light bulb 21W

rear signal light 100 mA (0.1A)
original light bulb 21W

rear brake/position 100mA+50mA (150ma)
original light bulb 21W/5W

Attachment 4739Attachment 4740Attachment 4741Attachment 4742
Attachment 4743Attachment 4744Attachment 4745Attachment 4746

new signal relay is ready
original diagram was published on tehniq
i have modified it for our needs


biggest current is 50mA x4 when all 4 lamps are lit
so max current must be arroud 200 mA
i took 1A to be shure so for command i used an BD237
Q1=Q2=BC171
Q3=Q4=Q5=BD237

and also i have atached my simplified diagram

price for simplified diagram 3USD

Attachment 4754Attachment 4755Attachment 4756

solar pannel has arrived

36v 7A on load (252W real/250W rated) so i will need an dc2dc conv for 144v

dimendions 1000x1500x5 mm
price 200USD

will replace car roof and blend into the car


update
i will change the
36v 7A on load (252W real/250W rated)
dimendions 1000x1500x5 mm
with
36v 5A on load (180W real/180W rated)
dimendions 900x1100x5 mm
price 180USD
because the big one cant fit on the top of the car
and add an new one on the hood later

Attachment 4768Attachment 4769

update

buyed 4 rims with new tires for the car
195x50x15"
12kg each new tire+rim

searching for an new carbon hood to be lighter than existing one
searching for new bumpers



Attachment 4774

Wow, you don't stand in one place long do you?:thumbup:
Keep 'em comin' jerpelea, you be Mr. Dynamo! :D

Eric

info update
car is at car repair and is coming along nice
now being disasembled and cleaned for rust


after some searches for electrical part we need
1.dc-dc converter 36-144v (500W)
2.ac-dc converter for 110/128v generator (5Kw)

so we need to buy/build them

i have found an drawing of what i want it to look
(bumpers and dors )

Attachment 4776

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

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

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

Attachment 4801Attachment 4802Attachment 4803Attachment 4804
Attachment 4805Attachment 4806Attachment 4807

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

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 !!

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
:thumbup:


Attachment 4809Attachment 4810Attachment 4811
Attachment 4812Attachment 4813Attachment 4814

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

Nice job on the tail lights. :thumbup:

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 :D
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

Attachment 4820Attachment 4821Attachment 4822
Attachment 4823Attachment 4824Attachment 4825
Attachment 4826Attachment 4845

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


Attachment 4846Attachment 4847Attachment 4848
Attachment 4849Attachment 4850

also 12v-220v inverter (500W) has arrived
it will be used for solar pannel chardger (240W/h top)

pictures atached
i will need to remove some cooper from transformers (2x 12/220v - yellow ones) to get 144v but now is working on 220v

for now i have plugged 300W halogen lamp and convertor is working nice
i have top 240W from solar pannels so is enough for me

for test the converter is plugger afer the modified computer power supply and i have tested both and are working nice

i am wainting for new solar pannels to test it in real life :thumbup:

this converter also needs an new sealed case made from cooper and i need to remove the fan

Attachment 4851Attachment 4852Attachment 4853

in car panel computer

modified eeepc 701 4G 7" display
can be used to get real time data from controler using RTD Explorer


power used less than 12W

can be foud on ebay around 100USD

now i need to find an case 225x140x40 for pc (i will use eepc LCD frame)
i have ordered an touchscreen interface so thet you can access menus and type without keyboard price 30usd

Attachment 4941Attachment 4942Attachment 4943
Attachment 4944Attachment 4945Attachment 4946
Attachment 4947Attachment 4948

update


144-12v 2x17A converter is almost ready (now packing in case for car instalation)
144-12v 4A for computer and controllers is ready (now packing in case for car instalation)
12-144v 500W inverter is ready (fets changed,transformators rebuilt) (now packing in case for car instalation)

220-144v car charger (testing small scale)

10-12batteryes BMS is ready (in testing phase)

car computer is almost ready (waiting for touch screen)


i will updload pictures later

dc - dc converter is ready almost finished assembling it
now we have the down converters ready
144-12v 17x2A for lights and breaking pump
144-12v 4A for pannel computer and controller

2 independent converters in the same box

i have removed impute ac-dc bridge and i am injecting dc directly into it

i have also moved all power components to the big aluminium heatshinks



Attachment 5005Attachment 5006
Attachment 5007Attachment 5008

waiting for the rest of parts

for now working on batery monitor

we need to know if batteries are leveled so me measure each batery and use an 10 led bargraph to indicate its state

10 identical 12V bargraph voltmetters based on lm3914

bargraphs are easy to read when driving !
we have an digital volmetter to measure battery pack voltage (whole pack)
and this bargraph to measure the remaing power for each battery

we have chosen 10 leds bargraph (DC10GWA) with last 3 red to know when the batery is nearly deplition (11.2V) so that we will not destroy the battery

also voltage levels can be ajusted individualy

for separation we have used quadruple optocuplers (3 of them) to be shure that high voltage can not break anything

this can be mounted on secondary radio bay or in our case in the center on console (where were old warning lights for preasure,etc...)

cost for the whole 10 voltmetters is around 20USD

Attachment 5011Attachment 5010

DYI Dolar charger
 

i blew the chinese 500W converter at tests with 200W halogen bulb in around 2 hours

upset i decided to build my own

it consists in 3 blocks
clock generator with 555
flip flop switch 1/2 of 4013
power block 2 BUZ48 for every 250W of load
i have reused the old ferite transformer and rewired it for my needs


i have tested this converter with 200W load for 1 day and is still working
(not from the test battery but from my 12V 2x17A dc source ;))



for battery charger it needs an ac/dc rectifier and an operational as comparator (to monitor charging currrent and stop charging at full battery)


final one has 4 fets (to be shure that it resists in time and prevent overheating)
i have also added 2x200cm2 aluminium raditors
now everthing stays at 43C

price 18USD


Attachment 5014Attachment 5015
Attachment 5016Attachment 5017
Attachment 5018Attachment 5019

This guy doesn't waste time!

Start investgating cheap/small brake pump
i have used an tire compresor that can go to 12 atm and reversed the valve
now i am searching for an vacuum tank 1-2l so that we can stop the pump and start it only when preasure goes below 4atm

the pump is realy small 80mm by 35mm and realy quiet (can be heard :( )


cost of pump with gauge 7 USD


Attachment 5020Attachment 5021

finaly some progress
car came from painting ...
now the real work begins

that looks great!

finlay back is finished with tail lights
photo taken in midday with sun lughting from my back (cant be worse than this)


now
lets start building the front


Attachment 6361

sorry to barge in on you (scuze ca dau buzna :D) but what else...I'm hooked to this now... :D

Have you tested your tire compressor vacuum pump further yet? I built one too, it went easily to 20 in/Hg. It wore out in use though, didn't build vacuum fast enough anymore. Had to get a "real" one from salvage yard. I used an old fire extinguisher as vacuum tank. Should be cheap, hehe.

I loved your idea of building led tail lights that way. I did the same: better than original.