Electric car parts list ForkenSwift com

2 Апр 2014 | Author: | Комментарии к записи Electric car parts list ForkenSwift com отключены
Daewoo Electric Cars

EV parts list for the conversion. reuse, recycle!

Here’s a of the parts/components used in the conversion. all were previously enjoyed most of the major ones are an old Baker electric forklift. some golf cart thrown in for good measure.

vehicles: 1992 Geo Metro + Suzuki Swift

Drivetrain: wheel drive, with 5-speed transmission (clutchless)

conversion, both of these were destined for the jaws of the crusher. The 1993 Suzuki was the first vehicle purchased the project’s nickname), but it turned out to too much underbody corrosion to be saving. So we bought the 1992 (in much better condition) and the Swift’s best parts to it.

The Metro passed its safety (in ICE form) with a grand of $79 CAD invested.

Additional info these host cars:

motor: series wound DC, Baker forklift

This 8 diameter, 50 kg / 110 lb motor (with splined shaft) originally one of 3 hydraulic pumps in the Baker from whence it was salvaged.

It was made by Otis, according to Jim of Hi-Torque Electric. It’s a little motor, he told us, for over-volting. It’s got four pairs, and a cooling fan built in the end.

Its biggest drawback was its internally shaft (see coupler below).

Adapter plate:

We made the adapter plate mounting the electric motor on the original transmission) from a of 5/8 aluminum plate. We drilled the for the transmission housing bolts; the aligned holes to mount the on the plate were made by a friend.

Additional info:

shaft coupler: adapted/custom

The that joins the motor to the was the most complex design of the project because of the hydraulic motor’s female (internal) shaft. We started with 3 the matching male shaft from the forklift’s hydraulic a Lovejoy connector with spider bushing; the female clutch hub (which fits on the input shaft).

We bored out one of the Lovejoy connector and inserted/welded the hub in place; Then our machinist cut down the pump shaft and it in the other half of the Lovejoy. He a set screw to the clutch hub half to it in place on the input shaft. with the motor, adapter coupler and transmission at his shop, he aligned everything and drilled the mounting holes on the adapter

Note: a Lovejoy coupler a rubber bushing is best to a low/medium power conversion. connections (clutched or taper are probably better options for power cars.

Motor Curtis 1204-412 (golf

The car has had three progressively more golf cart controllers it went on the road. Currently using a rebuilt 400 amp 36/48 controller from a Club Car cart — great find (cheap!). Much power in reserve than the 225 amp we originally started out with, and better than the 300 amp one used in between.

Much more about the car’s controllers:

eight Exide GC-5, 6 flooded lead-acid golf batteries (48 volt pack)

The car has had battery packs to date:

the car started out with a scrounged up of VERY used Powr-Surge T-105 equivalents from the that sold us the forklift. were half-dead (and mis-matched batteries. Good for testing, for building the battery and for and a couple of test drives the block, but not much more.

A big came when we were a second-hand set of Exides from EV owner. These 3-5 year-old were good enough to our minimum range target of 16 km (10

On Hallowe’en 2008, we bought set of new to us used Exides. These were approx 1-2 years old and evenly balanced than the second-hand pack. Range increased nicely.

Photos and info about the car’s and battery racks:

Charger: Technologies QuiQ

The QuiQ is a purpose built EV charger: 48 110/220v capable, 3-stage charger. Plug it in forget it it’s wonderful! Sample time: 7 hours @ 110vac driving 26 km (16 mi).

Before the we were using a Vulcan EA (24v/10A) charger meant for an floor sweeper, by splitting the to charge in two parallel 24v strings. A bit of a 24v/10A was very slow sometimes more than hours depending on depth of

As well, because the charger was longer than designed two strings), it got very hot, and we burned out a component on its circuit

Potentiometer (pot) box: Company (from Baker

This forklift potbox is with both high- microswitches. The actual forklift itself couldn’t be used the Curtis controller requires a pot, and the forklift’s was a 2-wire It was replaced with a Radio 0-5k potentiometer connected to a gear set to match its full to the throw of the potbox arm.

Contactors: GE (from forklift)

very big relays, the two contactors in the car are GE 36/48v rated units the forklift. They’re primarily for safety, to connect/disconnect the controller the batteries motor. (Controllers can fully shorted — IE. throttle — so it’s to have a method to break the should that happen.) One opens/closes every time the is pressed/released (via the low-pedal in the pot box); the other is switched via the ignition key switch.

Emergency Anderson connector (forklift) / pedal

The last line of in the event of a short circuit is a battery pack disconnect in the of a large Anderson connector to the car’s clutch cable. the pedal, and power is disconnected the batteries and the controller/motor. (And it disconnected when the pedal is

High voltage cabling from forklift; also welding cable; custom

The battery interconnects, motor and high voltage cables are a of 3/0 size locomotive cable the forklift and used 2/0 welding

Lugs at the end of each cable are original (in the case of on forklift or custom made. The custom ends were made by the cable ends, dipping in molten solder, then them flat with a file.

DC/DC converter:


Picked up a pair of 48v/12v 100 modules off eBay for about $25 It converts the 48v of the battery pack to approximately 14 volts to run 12v accessories lights, signals, wipers,

It’s not very powerful, putting out something like 5 at 12 volts, so sometimes the accessory needs to be topped up with a charger after running the and wipers. (Alternatively, I have the ignition ON (powering the DC-DC) driving, to top up the accessory battery.)

ammeter, custom LED battery monitor

600 Amp ammeter shunt . on eBay, this is the only new part on the car! (Still got it at a price though!) This current from the batteries, and is for driving efficiently (keeping low) or when a lot of power is (to decide which gear to use to get current).

Custom LED battery pack Prior to getting this an EV builder in the UK, a cheap digital was used to monitor voltage on the weakest battery in the pack. The LED looks like a sound equalizer — each shows the voltage of one battery. voltage is important because damage can occur if voltage is to drop too low under load.

sunshine, and a hair dryer

The car was in its first winter after but not in its second. Its range performance are less (because the batteries are not so it’s less practical. heat was wanted, the car was parked in the sun to it up, or before particularly chilly a hair dryer was run inside the for 20 minutes to pre-warm things.

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