Douglas De Boer's 1998 Plymouth Neon | Electric Cars and Hybrid Vehicle - Green energy

Douglas De Boer’s 1998 Plymouth Neon

11 мая 2014 | Author: | Комментарии к записи Douglas De Boer’s 1998 Plymouth Neon отключены
Plymouth Electric Cars

1998 Plymouth Neon

Plymouth Neon Highline


CHARGER DETAILS*******************

On Board Select-A-Charge Model

120 VAC(RMS) 60 Hz input

Nominal 144 VDC at 10 output

The charger is permanently in the trunk. This allows me to wherever I can find a standard 120 V outlet.

This charger is set up a 3-stage charge profile.

1) charge at a constant 10 A until reaches 174 V. During this of charging the voltage of the battery slowly rises from it was at the beginning of the charge to 174 V. When it 174 V that causes the charger to to phase two. The initial pack voltage could be low as 130 V but typically it is about 140 V to 155 V.

2) Gas (equalize) at a 174 V for 3 hours. During this of charging the DC current to the batteries from 10 A down to about 1 A.

3) at a constant 163 V until unplugged. this phase of charging the DC current to the batteries is typically than 1/2 A.

In my experience, this is a good value for the money, but marginally adequate for my needs. satisfied and have no plans to the charger, but others might a charger that works

The charger has a power factor of 0.75, which is a bit low. means you will want to it into a 20 A circuit and to have heavy wiring from household AC service panel to the and a heavy and short extension to the charger on the car. The charger to draw about 15 amps or a more during the early of the charge cycle.

Even this setup, it can take than 12 hours to achieve a charge after driving than 20 miles. If you put this at the end of a cheap 100 foot extension (cheap = 16 gauge, 100 feet = 30 m) you can a full charge to take than 20 hours. I’ve it!

If I were going to extend the of this car by improving the batteries, I would definitely change to a 240 V Even if I routinely planned to about 15 or 20 miles every day, I’d upgrade to a 240 V to make charging faster and convenient. I’m using the car on about 4 or 5 miles per day.

RANGE DETAILS********************


Actual driving experience 30 miles range in city with good performance speed of 55 MPH achievable) and less 60% of the battery capacity used.

The car was for 20 miles range in city using about 60% of the battery energy capacity. Actual is a little better than

A voltmeter is used to estimate while driving. I occasionally use a to make a final determination of before recharging and to improve my to estimate state-of-charge based on readings.


shows about 20 miles of driving on 55 MPH roads is realistic.

prior to building the car promised up to 40 in flat level driving at a 55 MPH and running the battery down to 20% Reality is that the roads are not and level and that as the battery goes below about 50% (at 20 miles range) the batteries can no provide enough power to 55 MPH on up-hill driving. Thus, if the batteries can provide more one does not enjoy driving the car way.

If you are using a simulation to range, you need to include the of hills and stopping and accelerating to speed occasionally, as at stop


______________________Project Diary______________________

*****January 17, 2009*****Conversion work

Started removal of gasoline and related parts.

*****May 6, Voyage********************

Maiden voyage on power. Traveled about 2 Some instrumentation and on-board were not yet installed. A loose cable to the transmission caused shifting.

After this the car went back into the to fix the transmission cable and add instrumentation.

7, 2009*****Sioux City Journal***************

On May 7 there was a front page in the Sioux City Journal this project. The text of the can be found here: WebPage The article was picked up by the Siouxland Journal WebPage (link no works) and later in abridged by the Doon Press.

*****May 11, City Journal Web Update******

On May 11 the Journal posted a video to the May 7 front-page story. WebPage .

4, 2009*****Sioux City Journal car

On Thursday, June 4 the Neon was again mentioned in a Sioux Journal Article. WebPage Show Shine car show was by rain to July 11, 2009.)

4, 2009*****Parade********************

Put the car back on the road, now instrumentation. Drove it in the city of Center’s Show and Shine car on Friday, June 6. Continued the car around town for personal use June 15, 2009. Put on about 32

*****June 15, 2009*****Install Charger***********

in the shop for installation of the on-board High voltage wiring was re-routed to a more secure

*****July 10, 2009*****Show and Shine car

On the road again, with charger. Will show the car on in the Sioux County Fair’s and Shine event.

*****July 11, Best Mopar**************

The Neon won the Best Mopar award at the Sioux Center Show and Car Show, held at the Sioux Fair. There were no electric or hybrid cars at event. The other cars either restoration cars, from the 1930’s to the 1970’s, or up recent models.

The Neon was recognized for the uniqueness of the changes to this car and the amount of modification this car had undergone.

*****July 25, Mentioned in NW Iowa Review

In the July 25, 2009 edition of the Iowa Review (newspaper) electric car is mentioned in an article Dordt College’s engineering

*****August 7, 2009***** 37 Mile Proven *******

Between 4 and August 7 I drove the car 37 miles in driving. At the end of this span the car was lazy and could not easily a speed over 45 MPH any more, but be driven in city traffic The specific gravity of the battery just before recharging was indicating about a 30% state of according to the battery manufacturer’s

*****August 10, 2009*****New Transmission Tires*****

The transmission oil has been with the Mopar brand recommended oil. (The had been re-filled with manual transmission oil after the was re-installed with the electric The factory specified oil is lighter then the generic. This improve the driving range a As a small side-benefit, the transmission with less effort

The tires on the car have also replaced with used (brand) tires. Nothing but the tires that were on the car worn down to the tread indicators. Now there is about 1/4 of tread on all four tires.

August 10, 2009*****Another Car Show*****

car will be shown in the Rock Iowa Rally in the Valley car Saturday morning, August 15, The car will also be in the parade in Valley that same

*****August 15, 2009*****3rd Place In Car

On Saturday the Neon Re-Volt third place in the Late modified car category in the Rally in the car show, held in Rock Iowa on this day. The car was part of the Rock Valley parade, also held day. Rock Valley is 15 from Sioux Center.

The car is garaged in Sioux Center. On evening I drove the car from Center to the Rock Valley school and plugged it in to re charge in shop. On Saturday, driving to the car in the parade, back to the car show, and back to Sioux Center the car put on 20 Fifteen of those miles on the highways at speeds of 55 MPH.

At the end of trip the specific gravity in the pack was 1.230, or about 75% (3/4 Full) according to from the battery’s manufacturer. The draws about 150 to 200 A to maintain 55 allowing for average hills. is a steeper hill (uphill) east out of Rock Valley on US 18.

The motor drew 250 to 300 A on this

I also taped a thermocouple to the for these trips. The thermocouple was at the transmission end of the motor where the internal fan exhausts air. The air was about 10 to 15 degrees F warmer ambient while driving on the (The motor also has a temperature limit switch in the box.

I have connected to an ohmmeter that beeps the circuit is closed. I have tripped that to date. I’ll get this permanently to an idiot light on the dash The motor controller is the next I’ll monitor for temperature.

It to run a bit more than 15 degrees ambient, but it has never been too hot to your hand on it indefinitely, after these highway to and from Rock Valley.

15 mile jaunt on the highway is the sustained high-speed trip the car has to date. It did well.

****August 19, Be In The Ireton Car Show *****

have been finalized to the car in the Ireton Show and Shine car on Saturday, August 22, 2009 2 to 4 PM.

****August 29, 2009****Watered Batteries Connections*****

Up to this time the have not been watered the time when I purchased Last week I noticed a few with just about 1/8 of water over the plates to charging, so it was time to water the for the first time.

Most of the took about 1 ounce of (30 ml) although a few needed none and a few about 2 or 3 ounces. I suspect the batteries were not uniformly when they were Overall the entire battery took about 3 quarts 3 liters) of water.

In the process I one of the connections to a battery was visibly This same battery had acid that had wept out of one of the ports and left a damp on the top surface of the battery. This me to disassemble and check all the battery but I found little other

Since I had each connection each got cleaned and re-assembled, but it now this is not necessary unless is visible corrosion.

I cleaned the top of the that had the corroding connection. I it with a disposable paper dampened with an ammonia-based cleaner. I used ammonia it will neutralize the acid and ammonia will evaporate and the top of the battery clean and dry with no I checked for electrical leakage and after cleaning.

I used a for this. I connected the positive of the voltmeter to the positive battery then slid the negative of the voltmeter around on the plastic top of the looking for voltage. Before there was voltage present on the surface due to the acidic dampness.

After cleaning, no voltage.

BTW the car a pleasing amount of attention week (August 22) at the Ireton car

*****September 1, 2009*****Trip to Orange

I drove the car from Sioux to Orange City and back, a distance of 20 miles, without in Orange City. This is the highway trip done on one to date. The car had 5 miles of around-town from the time of the most re-charge to the start of this The car did OK on this trip and could highway speed although for the few miles one could feel the car could not accelerate rapidly, as for what might be needed for a maneuver on the two-lane highway.

returning to Sioux Center I to drive the car around town for 6 more miles before The car accelerated normally in city after the trip to Orange Thus the car traveled a total of 31 on one charge, 20 of these miles at speed.

The specific gravity to re-charging was 1.190 or 55% state-of-charge.

9, 2009***** Mentioned in Akron

This car is featured in a story the Ireton Ag Day car show. The story is on 13 of the September 9, 2009 edition of the Hometowner (newspaper).

*****December 4, Batteries*************

I watered the batteries for the time in the life of these The entire set of 12 batteries took 1.3 gallons (about 5 liters) of The electrical connections all looked I made a small tool of a bulb on a plexiglass board 1/2 inch by 3 inches, a screw the plexiglass to probe into a and a jumper wire with an clip on it.

The light bulb has one connected to the screw (probe) and the connected to the jumper wire. I the screw (probe) so that the end of the was at the desired level of the electrolyte in a I connected the jumper wire to one of the terminals and added water the light turned on. I also about 12 feet of thin to siphon water from a jug on a shelf about

four above the batteries. I pinched the end of the to control the flow. These helped reduce the time filling cells to about an and a half. The last time I did (August 29, 2009) it took four hours. I checked all connections for tightness.

Most another quarter turn or so. the lead be creeping so as to let these get slightly loose?) There two or three battery connections a slight amount of corrosion. I they could be cleaned up when the weather is better.

14, 2009*****Winter Driving*********

Almost now people stop me in the parking lot to ask me how the car is in the cold weather. For the past (December 9 through 11 particularly) have been a bit below WebPage We have also had inches of snow. I’ve the car in several inches of loose now.

My experience is that the car really well in the cold and in the The lower center of gravity and mass given by the batteries it easier to control on slippery than it was as a gasoline powered The electric motor and controller and provide plenty of power for through loose snow.

The real effect of the cold is that I do not dare discharge the pack fully since might allow it to freeze. (I no heaters on the batteries and I keep the car in an garage.) I’m still using about 550 kWH per mile. If the weather is causing extra consumption, I’ve not noticed it

Many people also ask defrosting the windows since the car has no It turns out that this is not as of a problem as I had expected. In most just switching on the defroster fan the job without any heat.

Thus the car on the road and fully drivable in sub-zero temperatures most of the Other than as a creature the only time I’ve wished for heat has been in the evenings when frost is on everything. Then I have had to the windshield on the outside, only to it frosting up again a mile or so

Conclusion: In spite of the limitations of the electric cars are great for short winter trips. switch on and drive! None of rough idling, stiffness, and that you can get from a cold

There is no need to waste heating up a whole engine and related parts. Once I get a in my car I’ll definitely prefer it as comfortable and convenient on short compared to a gasoline powered

*****February 23, 2010*****One Thousand

On this date the odometer past 130532, which the first 1000 miles of driving. Considering that the car has in regular service since August, I’m driving the car 2000 miles per year. all of that driving is the kind of trips that rot out mufflers and sludge in the oil on ICE cars since the hardly has time to heat up the trip is over.

Instead, EV has been a stellar performer for kind of trips.

***April, Problems from Weather ********

This month I had a few with the 12 volt system. I noticed dim headlights, meaning the DC/DC converter was no longer the 12 V accessory battery (the old battery) charged. This out to be caused by a corroded fuse The fuse holder was located low in the engine compartment near the 12 V battery. Over the winter the got to it.

Eventually the corroded connection the fuse to overheat and blow. opened the 12 volt circuit the DC/DC converter to the 12 volt I cleaned up the corrosion and relocated the holder to a higher location.

I hope to replace the fuse with an entirely weather-tight holder.

A week later a 12 volt fuse blew This fuse provided 12 to the primary contactor, thus I all traction power and was left Being only two blocks home was fortunate—I could the car home without calling for a

The problem turned out to be a wire was free to flap around the bouncing of the car. It finally to the chassis. Moral of the story: all your wiring harnesses well.

We have practically all our harnesses in flexible plastic and held to the firewall, fenders, with adhesive cable Wouldn’t you know that one wire that was not so protected be the problem. And how frustrating to realize we left a very important unprotected!

Another weather-related is that I noticed some of the cable hanging about an (25 mm) below the bottom of the car. is the cable that brings from the rear battery to the front of the car. Apparently driving through some two of the cable clamps that the cable up got ripped loose.

The itself was completely undamaged. the is not even scuffed. We had used metal screws on the cable that held the cable up. were stripped right

I replaced the sheet metal with nuts, bolts, and This cable runs an area where the exhaust once ran. That also corresponds to the center of the floor of the car.

Even in that recessed snow put some force on the

*****May 15, 2010*****Battery Maintenance***************

and re-installed all the batteries under the seat and in the trunk for cleaning and Cleaned the tops of the batteries the hood. Checked all battery for corrosion.

Watered all the batteries.

one year into the life of the car as an car there is some minor of the battery boxes now. It this is caused by electrical through moisture and contamination on the surfaces of the batteries. I cleaned up the but did not re-paint the surfaces of the battery The largest area affected on a box is about three inches in (76 mm) and has not noticeably thinned the metal.

are about a dozen areas the size of a dime (18 mm diameter) or where corrosion has removed the but the underlying metal is still and normal-looking (gray in color) rubbing away the corrosion had adhered to the surface.

If I were to do project again I would the use of metal for the battery boxes. We the battery boxes from iron and sheet metal. The are about an inch deeper the batteries are tall. The boxes Plexiglas covers so that the can be seen but not touched when the car is on

It seems obvious that steel is needed for strength, but it to be kept away from the of the batteries, where the electrical currents seem to be the worst. Our battery boxes are completely inside with thermally foam. We chose an acid foam sheet—it is a type to insulate foundations of buildings. We expected that foam to electrical insulation.

The foam is an insulator, at least when it is But, small areas of the that were laying the areas of corrosion are now slightly If you press the probes of an ohmmeter on the you can measure some megohms of over a distance of an inch (25 mm) or so or the foam from one side to the

Clearly, acid from the is beginning to saturate the foam. I may to eventually replace the foam, though it looks like

Of the 24 battery terminals (two on battery) 5 had some minor I cleaned them up with window cleaner, then put a coating of grease on the terminals and them. The corroded terminals near areas of corrosion on the boxes.

Thus the corrosion to be enabled by electrical leakage damp or dirty exterior of the batteries. I expect some of the on the surfaces is due to water vapor during charging and some is due to as when the car is parked outdoors and dew forms.

A few days previously I had about 1/8 inch (3 mm) of electrolyte the plates in the cells after for 21 miles on one charge. This low is what motivated me to water the (I also checked the specific of one cell. It was 1.22 indicating a 70% state of charge.) Since the level rises as the battery is I first charged the batteries

That brought the electrolyte up to about 3/8 inch (10 mm) above the The whole pack of batteries took about 3 quarts of water to raise the level in the to about 1/8 inch (3 mm) below the plastic edge of the fill which is also about 5/8 (16 mm) above the plates in the cell. works out to about 1.3 fluid (about 40 ml) per cell.

This is two quarts less water I used when I last the batteries on December 4, 2009.

I checked the specific gravity of a few after a full charge and before adding water. The I checked were all at about All batteries (6 cells per battery) within 0.14 volts of other.

In short, the battery appears to be in very good A day later after watering the and after some driving and full charge cycle, the gravity was 1.28, probably a bit due to the additional water recently to the cells. (The battery specifies that fully the specific gravity should be

Removing the covers from the boxes takes about 30 (Ten minutes per cover, covers). Re-installing them about the same amount of again. Watering the batteries 72 cells) takes about 90

Thus watering the batteries about two-and-one-half hours. All the work, cleaning battery and terminals and investigating the electrical through the foam insulation of the boxes, etc. made it a project. Doing this or three times a year to be what will be needed to the car in good condition. I’m by the value of minimizing this time. I like electrical but this work is just work.

While designing the car we did not much about how long it take to remove the cover of a box, etc. Some in the design could have maintenance time.

*******May 28, Be In Show And Shine*****

I’ll be the car on Saturday, June 5, 2010, 10 AM to 2 PM (weather permitting) in the 21st Show Shine Car Show as of the Sioux Center Summer WebPage The car show will be on the side of Central park in Center, Iowa. Central is located on US Highway 75 between 4th and 6th NE.

******August 8, 2011******Watered the Batteries********

The batteries took 2.7 gallons. I topped up the accessory battery for the 12 V Connections were cleaned and as needed.

*****Oct 27, 2011*****Status

The Neon Re-volt continues in service. Other than adding water to the batteries no maintenance work has been since the May of 2010. The car is proving very reliable.

******January 3, the Batteries******

The traction batteries 1.33 gallons. The battery were clean—practically no corrosion.

8-9, 2012*****Car Show***************

I the Neon Re-volt in the Sioux Summer Celebration Cruise parade on Friday night and displayed it in the Sioux Center Celebration Show and Shine Saturday. The car still draws attention.

******July 18, 2012*****Watered

The traction batteries took 2.7 of water. I also topped up the battery for the 12 V system, which is the starting battery.

*****August 2012*****Car Show***************

I drove the Re-volt in the Rock Valley, Rally In The Valley Cruise parade on Friday night and displayed it in the Rally In The Valley Car from Noon to 3 PM Saturday.

27, 2012***Watered Batteries***********

The traction took 3.5 gallons. I did nothing the accessory battery as it seems to less frequent watering. were a few connections with corrosion in the battery pack the rear seat.

They probably need to be cleaned up the next summer (when the is nicer for that kind of

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