evtv friday showsmedia.ev-tv.me/rickard evtv friday shows thru 7-2-10.pdf · evtv friday shows july...

Jack Rickard EVTV video library - web.me.com/mjrickard/

EVTV Friday ShowsJuly 2, 2010...................................................................................................................... 2June 25, 2010................................................................................................................... 3June 18, 2010................................................................................................................... 3June 11, 2010................................................................................................................... 3May 28, 2010................................................................................................................... 4May 21, 2010................................................................................................................... 5May 14, 2010................................................................................................................... 6May 7, 2010..................................................................................................................... 6April 30, 2010....................................................................................................................9April 23, 2010..................................................................................................................10April 16, 2010..................................................................................................................11April 9, 2010....................................................................................................................11March 26, 2010............................................................................................................... 11March 19, 2010............................................................................................................... 12March 12, 2010............................................................................................................... 13March 5, 2010................................................................................................................. 13February 26, 2010............................................................................................................13February 19, 2010............................................................................................................13February 12, 2010 - Speedster Duh.....................................................................................14February 5, 2010..............................................................................................................14January 29, 2010.............................................................................................................14January 15, 2010.............................................................................................................14December 18, 2009..........................................................................................................15December 4, 2009............................................................................................................17November 27, 2009..........................................................................................................18November 13, 2009..........................................................................................................19November 6, 2009............................................................................................................20October 28, 2009.............................................................................................................21October 16, 2009.............................................................................................................22

EVTV notes 1 of 23


July 2, 2010

1 Tesla IPO, Tesla Roadster, GM Chevy Volt hybrid, X-prize 2 [17:50] test drive tweeks

2.1 [18:00] front end high, adjustment on Beck chassis 2.2 1986 lbs curb weight without rear trunk, 60% rear, 40% front weight distribution 2.3 [19:30] tachometer malfunction above 3500 RPM, “electric generator” at high speed

2.3.1 resistor added to prevent circuit acting like generator at higher speeds, 1/4 watt, 7.5 kOHM 2.4 [21:00] Xantrex connected to first 10 cells, draws 7 milliamps plus backlight to 40ma, but on all the

time, so over many weeks will draw down connected cells 2.4.1 [24:30] Vishay 10w power resistors, two 1K and one 500 ohm

resistors = 2500 ohms; 125v/2500 ohm = 50 milliamps, 5k pot 2.4.2 new assembly will draw from entire pack, about 1 Ah per day so

long term storage is an issue (one month would draw about 15% of entire Thundersky 36-cell pack)

2.4.3 http://www.mouser.com/ProductDetail/Vishay-Dale/RH0501K000FE02/?qs=sGAEpiMZZMukHu%252bjC5l7YWZuL2P47FOvtPV6qjLVYCE%3d

2.4.4 can put switch on Xantrex to cut off power when not in use 2.5 Lascar Electronics voltmeter display, $59

2.5.1 EM32-1B-LED 2.5.2 http://www.lascarelectronics.com/temperaturedatalogger.php?

datalogger=109 2.5.3 runs on 5v and requires isolation from measured source 2.5.4 micro DC-DC converter

2.5.4.1 RF1205CS-2W takes 12v converts to 5v up to 2w 2.5.4.2 http://www.lightobject.com/1205S-DC-DC-5V2Watt-

Isolated-Power-Module-Ideal-for-12V-system-P412.aspx 2.5.4.3 $9 2.5.4.4 1 meg and 1k resistor to allow 120-130v range 2.5.4.5 alternative to reading voltage from Xantrex and Curtis controller

2.6 [34:15] temperature, test drive with pump, heat exchanger off on warm day, 40-50 mph drive, moderate stress 2.6.1 reached 87̊C on Curtis controller indicator, which is 2 degrees over

threshold, thus triggering current limit to reduce heat (and thus degrades motor performance)

2.6.2 even with current chill plate size, needs additional cooling system 2.6.3 heater exchanger under transmission not sufficient 2.6.4 with new converted oil cooler, only reached 63̊C, well under threshold

2.7 contactor box, added temperature controller 2.8 plastic lids added to battery boxes to protect 2.9 Mooneyes vs classic hubs 2.10 value of regen, 1.009 Ah per km on Speedster Duh

2.10.1 three test drives a) full regenerative braking and neutral braking, b) only brake regen, and c) no regen 2.10.2 all in 2nd gear (current problem with 3rd gear)

2.11 [41:40] test drives 2.11.1 see EVTV blog for results

EVTV notes 2 of 23


June 25, 2010

3 Alex Smith BMS disaster 4 [50:40] Contactor Tyco Kilovac LEV200A5NAA relay (about $95) instead of

previous custom dual contactor assembly 4.1 http://www.onlinecomponents.com/buy/KILOVAC-

TYCO/LEV200A5NAA/ 4.2 PDF documentation http://www.onlinecomponents.com/goPdf.cfm?

pdfFileId=386888 5 [54:30} “Valet circuit” discarded, use 5k pot for adjustment instead, switch under

dash, see diagram on blog

6 Curtis controller handheld programmer demonstration 7 Speedster Duh test drive

June 18, 2010

1 Duane Ball 550 Spyder conversion with AC50 and 36 Sky Energy 180AH cells

June 11, 2010

1 [25:00] battery discharge profiles, see blog 2 [44:45] pressure transducer for regen on brakes - Digi-key MSP3251P2-ND ($104, 500 lb), MSP3501P2-ND

($104, 250 lb), 3/16” T-block for brake line with 1/8” NPT adapter from digikey.com 3 [48:15] Chennic foot throttle assembly, L-bracket mounting for two-hole new style, improved Hall Effect sensor 4 [51:30] Speedster build update

4.1 front battery box and terminal blocks, break in pack bridged with 1/0 and heat shrinked 4.2 [54:00] Chennic charger, with 10 pre-set programs that can be specified, 24a output; poor quality

connector to interlock 12v, at 3 amps terminate charge program => specify 4.2.1 “weather proof” charger: sealed without fan, silent operation, gets hot (insulate above for carpet),

possibility of using Comair fan to cool 4.2.2 set up for 3.65v per cell x 36 cells = 131.4v; charge 3.65v Thundersky specific; holds voltage as

amps decline to shutoff threshold of 3amps, then terminates gracefully

EVTV notes 3 of 23

Kilovac LEV200A5NAA relay


4.2.3 about 9 hours charging time on 120v AC, about 7 hours at 220v AC 4.3 heater works well with one element, Randy Holmes, Canadian EV source for heater

4.3.1 canev.com 4.4 defroster works 4.5 Xantrex connected across first 10 cells with APO fuse 4.6 Marinco side plug => NEMA 5-15 3-prong plug 4.7 Chennic Hall Effect 0-5v throttle mounting under dash 4.8 Valet-mode switch to reduce power 4.9 front, behind battery box: 13 x 6” aluminum sheet mounting platform for negative terminal block

4.9.1 junction bar, 600 amp rating 4.9.2 500 amp. 50mv shunt (Evolve Electrics) to parallel junction bar using bar stock, 26x10mm 4.9.3 Lem hass 200S Hall Effect current sensor 4.9.4 master negative terminal connection (red) 4.9.5 Xantrex connection 4.9.6 1-0 marine cable (yellow) connection to controller in rear

4.10 pressure transducer mounting on master cylinder 4.11 [1:21:30] distribution blocks under charger (front); charger is mounter “upside down” with indicator

lights pointing down and thus difficult to read 4.12 tach magnet mounting on flywheel in opposing placements using starter

motor hole in transaxle; starter motor cover plate 4.12.1 200mm, 130 teeth flywheel; JBWeld placement of magnets, paint-

side facing out, 65 teeth apart 4.12.2 Westach sensor mounted to cover plate, 5mm air gap (about $106)

4.12.2.1 http://www.evparts.com/search_results/index.php?section=products_zoom&TAG=in2551

4.12.3 connects to Beck harness, 3-wire: black ground, red 12v, green lead to tach

4.13 [1:27:50] front side of right aft battery box location for terminal block 4.13.1 orange cable to most positive of cells in battery box 4.13.2 10 gauge line to charger 4.13.3 DC-DC converter

4.14 rear engine compartment 4.14.1 battery box lids 4.14.2 fuse block mounted left side 4.14.3 fill reservoir bottle above motor, chill plate assembly

4.15 [1:32:00] negative terminal post, 1-0 yellow cable

May 28, 2010

1 oil spill update 2 disarray in EV community - EV Components, forum groups 3 [15:00] accelerator, out-of-control situation; mechanical potentiometer assembly, alternative is Hall Effect (John

Hall) in place of a 5K mechanical devise - had failure of accelerator “on” 3.1 Chennic with new Hall Effect sensor: green wire 5v out, blue 5v in, black ground, white and yellow for

microswitch qualifier 4 [20:00] valet “daughter” mode reduced power setting, also low-battery limp mode 5 [26:00] heat/temperature sensor to trigger pump for chill plate ($45) 6 [27:30] maintenance cutoff switch

6.1 Chennic cutoff installed in rear motor compartment 7 [30:10] Blue Sentry Lem Hass Hall Effect current measurement project with Roving Networks bluetooth device

7.1 http://www.lem.com/hq/en/component/option,com_catalog/task,displayserie/serie,HASS/output_type,

EVTV notes 4 of 23

Westach sensor


7.2 Digi-Key Part Number 398-1064-ND, http://parts.digikey.com/1/parts/1376203-sensor-current-200a-5v-bi-mod-hass-200-s.html

7.3 SENSOR CURRENT 200A 5V BI MOD - HASS 200-S ($26)

7.4 Manufactured by LEM USA, Ltd. 7.5 Roving Networks, Inc

(rovingnetworks.com) RN-800S-CB 7.6 Digi-Key Part Number740-1011-ND 7.7 BlueSentry Blluetooth Adapter contains

an 8 channel 16 bit AD converter (TI ADS8344) that samples analog signals and converts them to a Bluetooth-enabled digital data stream. http://www.rovingnetworks.com/bluesentry.php

7.8 plan to package in custom box, communicate with computer for output 8 [38:00] Curtis 1311 programmer 9 [38:50] maintenance main disconnect switch located behind driver seat

($186); used in Mini Cooper project. 9.1 Diesel Power Extra Heavy Duty Battery On - Off Switch

GIM2304A, http://shop.genuinedealz.com/Items/gim-2304a 9.2 "sweep contact" design, which provides a large, flat surface area

for maximum conductivity and efficiency without excessive wear 9.3 wire connects through fender well 9.4 A to fuse mounted on battery box 9.5 B through tunnel to front battery box

10 DC-DC converter mounting 11 [49:00] rear compartment wiring review 12 [55:00] Vantage neighborhood electric

vehicles, white van, discussion of technology, batteries, controller

May 21, 2010

1 news updates, Tesla, EV Components out of business, sourcing problems 2 [14:20] battery boxes, kevlar hybrid and carbon fiber cloth layout technique

2.1 [20:00] battery connections, M8 stainless steel bolt, lock washer, washer, copper strap with insulation in middle for connections within pack/box

2.2 1 awg terminal lug, 5/16” hole for connection in/out of battery pack 2.3 welding cable, orange, 1 awg UL General Cable Carol Super Vu-Tron P123-141

2.3.1 http://cgi.ebay.com/Carol-Super-VU-TRON-Welding-Cable-/390084552925 ($55/50 ft) 2.3.2 importance of flat surface and snug connection 2.3.3 different metals with various coefficients of expansion, so connections tend to become loose 2.3.4 Ideal Industries Noalox anti-oxidant compound to prevent terminal corrosion -

http://www.idealindustries.com/products/wire_installation/accessories/noalox.jsp 2.3.5 cable connection demonstration

2.3.5.1 heat shrink tubing with crimping, large crimping tool 2.3.5.2 surface-to-surface contact is key objective

2.4 [39:55] battery box construction 2.5 styrofoam block method

2.5.1 kevlar fiber , $20/yd, 4-5 yards

EVTV notes 5 of 23

Lem Hoss

Roving Networks Bluetooth

GIM 2304A cutoff switch

fuse mount


2.5.2 resin, $50-100 2.5.3 21 L x 12 W x 12” D approximate size; actual measurement 20 L x 11 3/16” W x 10 3/4” H 2.5.4 12 x 12 x 24 block (eBay) 2.5.5 styrofoam cutting, hot wire cutter 2.5.6 wrap with plastic tape for slick surface for inside finish 2.5.7 mold release 2.5.8 2-to-1 slow cure epoxy 2.5.9 initial cover of carbon fiber, 3 layers of kevlar, final layer of carbon

fiber (5 fiber layers) with epoxy 2.5.10 mount with aluminum plates acting like washers 2.5.11 polyurethane gladhands seals (used in truck air brakes)

2.5.11.1 http://www.easternmarine.com/Glad-Hand-Seals-4-Pack-12-0164/ ($4 set of 4)

2.5.11.2 inside diameter fits 1 awg cable 2.5.12 box lids

3 [1:21:50] chill plate reservoir mounting in notch of battery box (revised later) 4 [1:22:30] left battery box notch mounting of fuse, Ferraz Shawmut 300v 500a

May 14, 2010

1 news updates, scratch built cars, Aptera 2 GMC van conversion review 3 [40:30] BMS, cell drift myths

May 7, 2010

1 [2:30] Chennic charger JCWC126-24, mounted upside down (not optimal, but OK); chennic.com

1.1 set at factory with 10 pre-programmed charge curves in a band around voltages, with each band about 1 volt difference

1.2 mounting with 18 x 1 x 1/8” aluminum angle stock, with six 5/16” x 1 1/4” bolts - grade 8, and four 6 x 15mm bolts for brackets, using square drilled 2” section (two pieces)

EVTV notes 6 of 23

Charger mounting location with pre-drilled holes and fiberglass cutaway


1.3 cut fiberglass for supports using small hand tool 1.4 36 cells x 3.65v for Thundersky = 131.4v (suggest 121 to 131v range), $680

2 [20:10] Marinco plug 2.1 2 x 2 3/4” donut spacer 2.2 square mounting plate

3 [30:00] motor installation with jack, bolted with three 3 x 3/8” 16 and one 4 x 3/8” 16 3.1 fan plate and fan, about 1/2” clearance, two 1/2” bolts

4 [31:20] battery box installation 4.1 tight clearance 12” on rear right side, notch for coolant reservoir for controller chill plate

5 finned heat sink mini-radiator for chill plate mounted just underneath end of transaxle 6 coolant pump, Meziere, 12v, underneath

passenger seat 6.1 note grounding cable for transmission

to chassis (see photo)

EVTV notes 7 of 23

Mounted Chennic charger


6.2 Summit Racing AN6 hose

6.3 Curtis controller mounting

7 rear battery box (right), negative top upper left, in “snake layout”

EVTV notes 8 of 23

Curtis controller


8 Raptor fuse box (car audio industry source), 400 amp ANL fuse

9 [1:05:40] “Illuminati” electric car project

April 30, 2010

1 news update: EV Components collapse, Sunbeam conversion letter regarding BMS systems 1.1 [11:00] lineman's cable cutter “cutoff switch”

2 cutoff switch, emergency shutoff switch 2.1 Diesel Power Extra Heavy Duty Battery On - Off Switch GIM2304A,

http://shop.genuinedealz.com/Items/gim-2304a (see May 28, 2010 EVTV segment) 2.2 [12:45] emergency shutoff

2.2.1 Curtis Albright ED250B-1 250a 96v 2.2.1.1 http://www.thetoolboxshop.com/ed250b-1-albright-heavy-duty-

emergency-stop-switch-250a-96v-max-5210-p.asp 2.3 Jack accident, burned hands, need for cutoff switch

3 letter: diode on heater 4 letter: heater relay idea

4.1 [25:00] test of idea, eliminates wire and two diodes - works 5 [53:45] cold temperature Thundersky test 6 [1:02:15] AC50 HPEVS motor, 112 lbs with Curtis 1238-7501 controller 12 lbs

6.1 Canadian EV adapter (used in first Speedster) $825 6.1.1 canev.com 6.1.2 coupler system with taper lock (stock item $6)

EVTV notes 9 of 23


6.2 adapter to save space from ElectroAutomotive $825 but with inferior coupler

6.3 custom adapter Cape Precision $795 6.3.1 necessary to fit 36 cells

6.4 [1:12:25] assembly of adapter on AC50 motor 6.4.1 spacer on shaft 6.4.2 fit in hardened key 6.4.3 taper lock over key pushed all the way in

flush against spacer, key pushed back to stay in position

6.4.4 tighten taper lock set screw with 1/8” allen to keep key in place

6.4.5 flywheel adapter hub, tightened with three 3/16” allen bolts, rotate to tighten to slowly pull in taper lock

6.4.6 motor ring, flat side to flat side, fasten with four 5/16” allen bolts, using blue thread locker

6.4.7 mounting end plate with thread locker 5/16” allen bolts (countersunk for bolt heads)

6.4.8 stock 200mm flywheel with teeth, balanced 6.4.9 stock VW glan nut and wavy washer (usually part of flywheel package) fits over adapter hub

6.4.9.1 flywheel lock attaches to teeth to prevent rotation 6.4.9.2 torque glan nut

6.4.10 stock 200mm clutch disk 6.4.11 stock 200mm pressure plate, balanced (no locating pins), attach with thread locker 6.4.12 CB Performance bolt kit, 1369 6.4.13 VW pilot tool for clutch position

April 23, 2010

1 Mini Cooper update 2 [28:50] Speedster heater

2.1 Canadian EV canev.com 2.2 [47:00] heater and blower assembly installation

3 [56:45] Xantrex Link Pro ($234) , also Link Lite 3.1 http://www.xantrex.com/web/id/274/p/1/pt/5/product.asp 3.2 http://www.xantrex.com/web/id/273/p/1/pt/5/product.asp

(Link Lite) 3.3 data out port to connect to PC 3.4 has options for all needed info for EV: amps, amp hours, % of

charge, time, voltage, also menu has stat, hist, function 3.5 functions, auto reset, etc. 3.6 pre-scaler ($100-150) 3.7 Link Lite ($200) limited to 1000 amps, can configure shunt used 50mv or 60mv 3.8 not Hall Effect shunt accuracy, but acceptable; can use any shunt

EVTV notes 10 of 23

Cape Precision adapter with AC50 motor


4 [1:18:10] cut out fiberglass to mount battery boxes

4.1 bumper modification so does not project past rear horizontal beam (see above) to make room for battery boxes

April 16, 2010

1 Thundersky 200 Ah and Sky Energy 180Ah cell testing 1.1 same form factor 1.2 test charts, see EVTV blog

April 9, 2010

1 [7:50] Curtis controller contactor resistor custom box for Speedster Duh(later revised, see June 25, 2010) 1.1 dual Kilovac with bus bars, 12v 30a relay in circuit

2 [23:15] plumbing for Mini Cooper 3 [41:50] MES-DEA model cooling, controller plumbing 4 [53:20] Mini Cooper test drive

March 26, 2010

1 [2:00] Mini Cooper motor and adapter, MES-DEA 2 Mini clutch assembly 3 [55:15] motor, transmission installed after adaptor failure, spin wheel test 4 [1:03:05] BMW Z3 conversion

EVTV notes 11 of 23


March 19, 2010

1 Mini Cooper vibration, motor adapter problem 2 [17:50] motor encoder sensor bearing, SKF Group (skf.com) manufacturer

2.1 2-channel, 64-bit encoder - 64 positional locations about 6 degrees apart 2.2 controller uses to gauge motor position

3 [20:10] discussion of motor rotor, the moving part in AC motor 4 [21:00] motor basics, magnetic fields, heat generation, current

4.1 [23:30] core windings, I-beam segment, lines of force 4.2 capacity of motor related to amount of heat that can go

through windings in stator, and distance between stator surface and rotor

4.3 [26:50] AC induction discussion 4.3.1 current induced in rotor causes magnetic field, conflicting

magnetic fields force rotation 4.3.2 atomic force, magnetic fields

4.4 [32:00] AC motor voltage usually high, depends on windings, current causes magnetic fields 4.4.1 power is function of current (745 watts = 1 horsepower) 4.4.2 tradeoff between voltage and current depends on width of wire windings

4.4.2.1 comparison with AC50, will custom wind 4.5 advantages of AC motors

4.5.1 no brushes, no commutators to arc 4.5.2 regenerative ability (but see July 2, 2010

discussion showing lack of benefit) 5 [49:45] Speedster Duh Curtis 1238-7501 controller 3-

phase cooling chill plate, mated to AC50 motor 5.1 majority of EV conversions use Curtis 1231 but

they have known heat problems, so reputation mixed, and other controllers on market - Zilla, etc.

5.2 AC controllers difficult to find; Curtis manufacturers for fork lift applications

5.3 Wheego application 5.4 115v 550 amp controller matches AC50

motor, controller can handle up to 130v - with additional cells 38 x 3.35 = 127.3 volts Sky Energy 180 Ah 5.4.1 note: 36 Thundersky 200 Ah 36 x 3.4 = 122.4v 5.4.2 can get up to 76 HP with higher voltage

5.5 heat generation is limit on higher power output 5.5.1 Curtis controller manual: “... fastened to clean, flat metal surface with four 6mm 1/4” diameter bolts

in holes provided ... thermal joint compound ... additional heat sinking may be necessary ...” 5.5.2 linear cutback at 85̊C with full shutdown at 95̊C 5.5.3 [1:06:05] cooling options: finned heat sink with fan but mounting space limits in Speedster 5.5.4 chill plate construction

EVTV notes 12 of 23

Rotor

Wheego neighborhood electric


March 12, 2010

1 J1772 connector, recharging discussion 2 [34:00] Speedster motor install

2.1 adaptor fit with transmission, clearance with lower bolts (see photo)

2.2 [47:45] Duane Ball project for Spyder 550

2.3 [58:00] Comair Rotron fan attached to motor end (without end shaft model, same SKU as AC50 with end shaft)

2.4 [1:06:20] magnetic pickup (later revised)

2.5 adapter plate (later revised)

March 5, 2010

1 switching pack voltages 1.1 [02:20] contactor, can create arc when gap small, can be dangerous 1.2 discussion of bad forum advice

2 [28:20] Mini Cooper connections 3 [1:09:00] throttle debugging

February 26, 2010

1 news update: Tesla plane crash, Lotus concept 414E car, Getrag transmissions 2 [30:00] documentation issues, inaccuracies, translation problems

2.1 Chennic Technology 2.2 http://www.chennic.com/

3 [49:00] super capacitors 4 [1:02:00] accelerator pedals 5 [1:09:20] Chennic DC-DC converter 6 [1:12:00] Chennic charger, 10 charge profiles JCWC12624, 22 lbs

February 19, 2010

1 [29:00] Mini Cooper skid plate 12 x 36” construction 1.1 [45:30] skid plate install

2 [50:00] 3-phase A/C controller for Mini Cooper 3 [54:00]TIM600 controller for Mini Cooper 4 [1:02:15] mounting system for controller 5 [1:09:30] rear end adjustment for Mini Cooper, springs

EVTV notes 13 of 23

Speedster transaxle mount


February 12, 2010 - Speedster Duh

1 introduction to the electric version of the Beck Speedster

2 swing axle type last made in 1968 with short shafts 3 transmission gearing customized; 0.70 to 1 4th gear

February 5, 2010

1 Mini Cooper engine mount 2 [21:00] drive shaft 3 [38:00] rotor, caliper, brakes

January 29, 2010

1 Mini Cooper drive train, adapter plate, transmission, engine, clutch

January 15, 2010

1 BMS “madness” 2 [6:30] Cell Log 8S (Cell Voltage Monitor and Logger), $29

2.1 uses common 9-pin connector 2.1.1 Digikey 455-2217ND, JST XHP-9

2.2 monitors 8 cells 2.3 software for PC, including graphs 2.4 hobbyking.com (radio control helicopters)

3 limited value of using voltage to monitor pack

EVTV notes 14 of 23

Front battery box

Cell Log 8S


4 Sky Energy 100Ah (red) and Thundersky 90Ah (blue) cell profiles

4.1 discharge test showing load and then 60 sec rest (voltage recovers), static vs. load voltage, all at 1 C (about 5% of capacity of cell) 4.1.1 fall-off at about 80% discharge, so logic to using 80% threshold 4.1.2 China Aviation Lithium Battery Company LTD (China Aviation Industry Group investment) name

change from Sky Energy (blue cells) 4.1.3 flat discharge curve means that using voltage for measure not very useful except at very end of curve 4.1.4 state of charge indicator must use amp hour measure

December 18, 2009

1 [2:00] how batteries work; lots of mythology in the EV community about monitoring, management issues

2 [3:00] “watching paint dry” battery constuction and specs 2.1 2008 introduction of lithium prismatic cells, initial testing on

GEM, Speedster 1, now Mini Cooper 2.2 need to maximize life and potential of cell 2.3 cell constructed like phonebook with “battery” pages

separated by insulators, clamped on the anode side (right in photo) and cathode (left in photo) 2.3.1 copper anode coated with carbon graphite material 2.3.2 aluminum cathode with lithium iron phosphate 2.3.3 separator in between allows passage of lithium ions, LiP6

eletrolyte 2.3.4 chemical action on both plates; anode is actually carbon

graphite material, copper is collector 2.3.5 aluminum is collector, cathode is actually the LiFePo

EVTV notes 15 of 23


2.3.6 current flow back and forth 2.4 lithium cells generate high current flows, however if over-discharged cathode is super-saturated and

oxidizes the lithium, cannot be reversed (cell death) 2.4.1 lower voltage threshold

2.5 if over-charge, gas released from excessive electrons (vent on battery) but cells can swell up 2.5.1 capacity is function of spacing of plates 2.5.2 over-charging cuts capacity, but can mechanically squeeze cell casing back together (to limited

extent) 2.5.2.1 no thermal runaway due to over-charging (up to 30v per cell will gas, but will not explode) 2.5.2.2 can over-charge, if float at 3.4v nominal, can charge up to about 3.6v without harm (in fact,

some good) 2.5.2.3 cells tend to be self-balancing, slight over-charging gives minor balance benefit

2.6 [19:00] Sky Energy spec sheet 2.6.1 April 2008 bought first cell, new devise

2.6.2 Ohm's Law is basis of understanding: example 180Ah Sky Energy (but listed as 190Ah) 2.6.3 nominal capacity (190) in amp hours = 190 amps for one hour 2.6.4 energy density, energy per unit of weight; about as powerful as 4-5 lead acid cells 2.6.5 [25:30] float voltage 3.4v at 100% charge, open unloaded at instant one

EVTV notes 16 of 23


2.6.6 inner resistance; not very useful 2.6.7 operating voltage, charge 3.6, discharge 2.0v at 0.3c (see below)

2.6.7.1 standard charge charge/discharge current 0.3c (50 amps on 180amp cell) 2.6.7.2 max charge current 3c, so change charge up to 3 x 190 = 570a implies that rapid 20min charge

is possible at very high current (not practical) 2.6.7.3 max discharge current 4c for 30 seconds, up to 12c for 5msec

2.6.7.3.1 2100 amps per cell for 5ms (4-5 kW power for very short time) 2.6.7.3.2 example: heat shrink around wrench (see

photo) so cannot short out across terminals 2.6.7.3.3 if terminals are shorted with piece of metal,

instant 2000 amps discharged, can melt metal - do not wear metal watches, rings, wristbands around battery terminals - EXTREME HAZARD

2.6.8 cycle life, 70% and 80% DOD 2.6.8.1 very long cycle life, even longer if not at

extremes of capacity 2.6.8.2 for example, if under-charge and under-

discharge then much longer life, probably 25+ years 2.6.8.3 how determined, based on extrapolation from 200 cycles, curve suggests at 3000+ cycles cell

will still be at 70% of original capacity, actual useful life longer 2.6.8.3.1 if average trip to 70% DOD is 50+ miles, then pack/vehicle life is 150,000 miles+

2.6.9 [40:30] temperatures, broad range of operation 2.6.10 self-discharge rate 3% or less (compared to lead acid 20%)

3 [43:45] chargers and battery charging 3.1 constant current and current voltage curve, method of many decades 3.2 when charging, need higher voltage to charge to float level of 3.4v 3.3 IU curves for charging, LiFePO do not need multiple stages

3.3.1 proprietary charge curves in manufacturer's charger, not disclosed 3.3.2 need single stage charger with a set voltage level

3.4 different cells at different voltage levels, so some advantage at charging at lower voltage 3.4.1 for Sky Energy charge at 3.5 or 3.45 instead of mfg 3.6 charge level to avoid over-charging any

individual cell 3.4.1.1 range of individual cells typically from 3.48 and 3.55v Sky Energy

3.5 when reach target voltage (3.5 or 3.6v for Sky Energy) charging is not done: still need to charge as current falls

4 [1:00:00] charging demonstration 4.1 for Sky Energy use 3.45 or 3.5 x number of cells = target voltage

4.1.1 3.45 x 36 pack = 124.2v or 3.5 x 36 = 126v target at 3a cutoff 4.2 for Thundersky use 3.65, not 4.25v as on mfg spec

4.2.1 3.65 x 36 pack = 131.4v target with 3a cutoff 4.3 no advantage to charge to very top of mfg spec, avoid risk of over-charging

December 4, 2009

1 news updates: electrification roadmap 2 [27:15] Electric Vehicle Handbook 3 [48:30] Earlbacher Gear Works, machine shop for gears - used to fix Mini Cooper transmission/motor adapter

EVTV notes 17 of 23


November 27, 2009

1 news update: 2 [13:00] “OEM” misguided focus, IP only, no products 3 [26:30] SEMA in Las Vegas

3.1 AMP-D and Factory Five '33 Ford replica 3.2 Solid Works 3.3 UQM drive train

4 [30:00] ugly cars, incremental improvements - evolutionary process - thrown aside in EV design like Aptera 5 [35:30] peak oil discussion 6 [55:00] Mini Cooper roundup

6.1 fuse block and DME 6.2 pot for control of regen 6.3 [1:00:15] back pack

6.3.1 time-delay fuse location 6.4 sliding battery box system 6.5 [1:03:00] Guest cutoff switch

EVTV notes 18 of 23


November 13, 2009

1 BMS controversy 1.1 5000 miles on Speedster without any BMS system, at odds with EV community of BMS need 1.2 107 mile test drive => all cells at 2.8 and 2.9v discharged so “self-balanced” 1.3 Rich Redmond (example of EV BMS proponent) 1.4 charge/discharge curve contrast between LiFePO and lead acid cells 1.5 [5:00} linear decline (lead acid, top curve in photo) vs.

flat middle of lithium with sharp decline in beginning and rapid falloff at end (bottom curve in photo) 1.5.1 you don't want to be at either “sharp” end 1.5.2 instinct to be on safe flat part of curve 1.5.3 successful in Speedster for a year without any BMS

1.6 Rich Redmond has spent “thousands of hours” testing BMS and warns about losing cells without BMS

1.7 shunt charge balancers ruin cells, BMS is the problem, not the solution

2 [9:30] GEM neighborhood electric vehicle, 25mph limit 2.1 test mule for batteries

2.1.1 first use of lithium cells 2.1.2 Maxwell ultracaps tested 2.1.3 testing batteries is boring, Jack has

a few hundred hours 2.1.4 lesson from GEM showed the

differences with lithium cells => destroyed 3 Thundersky cells

2.1.5 discharge is greatest danger 2.2 Agilent 34405A multimeter

recommended, can measure cells to 1 mv accuracy, about $750

3 [18:00] custom test box, 3a 12v and submarine switch can select up to 18 cells 3.1 manually simulated shunt, charged cells to 4.00v exactly did test drive, had 3 dead cells 3.2 why did this happen, in contrast to Speedster without any BMS or balancing?

3.2.1 so obvious, it's embarrassing: upsets the apple cart of BMS industry 3.2.2 [37:30] redwood sticks explanation

EVTV notes 19 of 23


November 6, 2009

1 ugly cars 2 [9:00] green vehicle plate, Ontario 3 [13:00] Professor Norbash presentation on electric cars

3.1 RAV4 2001-09 driven, zero maintenance, changed tires, no brake work since has regen 3.2 value of no maintenance not appreciated fully since people don't have them yet 3.3 Prius sticker 52 mpg EPA rating, but lower number in the highway, reverse of ICE 3.4 ICE is so inefficient that air resistance/drag not noticed 3.5 regen braking 20% range claim, skeptical ... perhaps 9%

3.5.1 RAV4 data => 27% savings (but see July 2, 2010 debunking) 3.6 switching ultracaps

4 [19:30] charger for 2009 Mini Cooper Clubman 4.1 preliminary goal of 150 mile range, depending on regen benefit 4.2 192v charging, 3.5v per cell so stay below mfg recommendation charge max 4.3 BMS debate raging on 4.4 new Thundersky 200Ah cell announced, technical improvements month-to-month

5 Brusa previously charger of choice, but limited power would be 9-10 hours to recharge; built in Switzerland, programmable, $3200 previously and now $3900 5.1 isolated chargers with transformers 5.2 could use two Brusa chargers, have a function to share charging task

6 [28:00] charger options, lithium batteries are game changer 6.1 [34:00] Manzanita, manzanitamirco.com, based in northwest

6.1.1 Rich Rudman and Joe Smalley, co-founders, met in college early 1980s 6.1.2 built EVs in 1990s 6.1.3 in 2001 designed PFC charger

6.1.3.1 more power emphasis 6.1.3.2 flexible, adjustable current to match environment, and use for different pack sizes 6.1.3.3 advanced in 2001, but not designed with lithium batteries in mind 6.1.3.4 expensive, various

models, from 30 to 75 amps 6.1.3.5 9 employees 6.1.3.6 have built 720 units,

about $500k revenue/year 6.1.3.7 hand-built, high quality 6.1.3.8 part of reason why EVs

are so expensive => cottage industry

6.1.3.9 early pioneer, like Cafe Electric (Zilla controller)

6.1.4 Manzanita PFC30 7.2kW can substitute for 2 Brusa chargers, about half the cost, 91.5% tested efficiency which is excellent

6.1.5 can charge Mini pack in 2.5 hrs 6.1.6 [55:30] Tweco welding connectors

6.1.6.1 instead of standard Anderson connectors 6.1.6.2 does cause “pop” when connected, so requires operating care 6.1.6.3 never run Manzanita without a load, so hook up to batteries

before plugging in unit to recharge 6.1.6.4 [57:00] modified method of using Manzanita charger

demonstrated, suggest pre-charge circuit like controller/contactor

EVTV notes 20 of 23


October 28, 2009

1 gas prices, energy policy 2 [11:00] Tesla accident 3 EV plugs, possibly what Chevy Volt will use

3.1 J1772 4 [31:00] Mini Cooper

4.1 high voltage terminal blocks, positive and negative 4.2 cable size based on length 4.3 welding quick disconnect, twist lock

4.3.1 do not like Anderson connectors, hard to connect/disconnect, can blowup, and also positive/negative combined in very small space => dangerous

4.3.2 use two different sizes so can't reverse polarity 5 [39:30] DC-DC converters

5.1 importance of treating pack in its entirety, not charging or discharging a portion of the pack

5.2 [45:00] kellycontroller.com line of DC-DC converters 5.2.1 idea of using multiple converters, problems of load sharing

5.3 [47:00] Brusa 412 brusa.biz, $2600 initially, now over $3,200 due to falling value of dollar 5.3.1 min 125v - 270v max, very efficient over 90% 5.3.2 use test scenario prior to “fitment” phase of installing in vehicle 5.3.3 initial test failed, blew fuse: amendment documentation => “pre-

charing circuitry ...” recommended 1-3 seconds otherwise high in-rush current will cause failure, issue not covered by warranty 5.3.3.1 solution is resistor 1k power across terminals of contactor, common for controllers, but not

generally used with DC-DC converters 5.3.3.2 to be connected on contactor side

5.4 [58:00] modified DC-DC converter 5.4.1 Vicor modules micr.com

5.4.2 V300A12C500AL

EVTV notes 21 of 23

Anderson connector


5.4.3 negative/positive input and output 5.4.4 maintains stable 12v output across wide input range 5.4.5 $275 each, 3 units => 1500 watts, about same as Brusa 5.4.6 common use on mainframe computers (not common in EV community)

5.4.6.1 as result, can find used at $20 each harvested from old mainframes 5.4.6.2 total isolation (5000v) with adjustable output by trim resistor; 5 output pins, sense (S) pins, SC

pin; see calculator online 5.4.7 requires heat sink with thermal grease

5.5 Vicor has balancing capability 5.6 [1:06:30] assembly of DC-DC converter

October 16, 2009

1 first weekly web TV show: The Friday Show 2 [6:00] shipment of Blue Sky batteries, 180Ah, different spec from Thundersky with 3.65v charge voltage vs.

4.25v Thundersky, both brands do not operate under 3v, but Blue Sky has fairly hard ceiling of 3.6 - 3.65 when charging

3 [9:30] Roland Berger, Powertrain 2020 white paper 3.1 BYD investment

4 [28:00] DC-DC converter 4.1 IOTA DLS-55 4.2 [30:20] Speedster project Vicor bricks 4.3 philosophy: build your own dream car with open source components, but reality is difficult

4.3.1 plan for under-$50,000 Speedster, perhaps under $45k 4.4 [35:20] need for isolated converter that does not unbalance pack, two options

4.4.1 Sure Power, 30a, $211 4.4.2 Kelly HZ1 series, 25a (compared to +75a in ICE) so less than 30a may not be enough power for

Mini, perhaps sufficient in Speedster

EVTV notes 22 of 23


4.4.2.1 vendor: ase-supply.com 4.5 [41:10] and [44:30] comparative chart IOTA, Sure Power, Kelly 4.6 low voltage solution, but not much available at high voltage except custom built

5 [51:30] introduction to AC50 motor and matched Curtis controller 1238-7501 5.1 reasonable price AC technology, released within the last month 5.2 low voltage AC drive train, vendor: Thunderstruck EV, mfg by High Performance Golf Cars, Ontario, CA 5.3 Curtis high market share of EVs (about 50%), but major business is fork lifts, golf carts 5.4 full features, programmable, limited to 130v

5.4.1 implies large cables to carry high amps and somewhat limited power 5.4.2 550 amps at 115v, can push to 130v 5.4.3 regen braking

5.5 smaller motor than WarP9 but uses standard adaptor plate

5.6 advantage: no brushes and regen (but see July 2, 2010 failure of any regen benefits in actual drive testing)

5.7 3 pulse-width modulators to control motor, more complex versus DC technology, although motor itself is less complex construction

5.8 micro-controller based 5.9 ordered programmer for Curtis, additional $500 5.10 controller on heat sink, need additional cooling, power is function of heat generation 5.11 130v at 550 amp => 71kW equivalent to 95 HP peak; original Speedster had 66HP and heavier steel

body; 115 ft lb torque, comes with small display unit, plans for improved display system

EVTV notes 23 of 23

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