![]() | #76 | |
BHPian ![]() Join Date: May 2005 Location: Pune
Posts: 190
Thanked: 1,152 Times
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Better is to convert to full electric and add a small engine as a range extender that kicks on and charges the battery when low | |
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![]() | #77 |
BHPian ![]() Join Date: Mar 2008 Location: CG/CH
Posts: 517
Thanked: 442 Times
| ![]() This is some really great stuff. Stupendous! I would say the following: 1. Stop posting on open forums and ensure you save your IP 2. Get a company registered and then market your product 3. Work out the maths (would you make more money by converting for the general public or maybe tie-up with some big manufacturer 4. Once the Covid situation is done, do proper road shows to market yourself. Surely web presence is a given. What percentage of your hardware is dependant on imports is a thing that you should be mindful of. Finally, All the best for the exciting times to come. |
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![]() | #78 | |
BHPian ![]() Join Date: Mar 2011 Location: Mumbai
Posts: 987
Thanked: 746 Times
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![]() | #79 | |||||||
Newbie ![]() Join Date: Jan 2020 Location: chennai
Posts: 8
Thanked: 16 Times
| ![]() Hi, great work, i completed the whole thread in one go, awesome conversion. I have some basic questions, looking forward learning from you, hope this will give a clear picture to other members as well, Quote:
2. With 3.2V 250Ah, your pack capacity is 12.8kWh not 15kWh. Assuming 5kW power required for 1.1ton vehicle to drive @40km/h(0.3 frontal area, rolling resistance 0.0075, no headwind, no aux load-power steering, vacuum pump, HVAC, etc), it would require 14.375kWh battery pack for 115km range. correct me if i'm wrong ![]() 3. How are you charging the battery within 45 minutes using fast charger, i can see only a blue industrial socket that is not good for 20kW continuous power. With current standard and charging technology you cannot charge 48V 12.8kWh battery pack within 1 hour (options are there, but that would cost the whole vehicle conversion cost) Quote:
2. Reaching 0% is not good for battery pack, can cause damage 3. I cant see any SOC indicator in the android tablet you have mounted on the dashboard. How you are safely using the pack without knowing SOC of the pack? I'm afraid i cannot even locate a voltmeter (which is not useful for LFP case in the first place) inside the cabin ![]() Quote:
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2. Hope you have not parked your car under direct sunlight in day time, if you are doing so, please change your parking. Search on google for fire due to power bank in locked car. Your beat is prone to fire due to high temperature inside locked car both from direct sunlight and heat from tarmac 3. LFP chemistry battery will also reach more than 300°C during puncture 4. I can only see copper busbar connection between cells. Even assuming the same is with fuse, how it will help in short circuit condition across one cell? Quote:
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Hope you will help us understand the safety and technical aspects of your EV conversion. In my opinion I would say, building an electric vehicle is simple and converting one is even simpler because it does eliminate all mechanical engineering. But the safety risk involved in operating and maintaining an EV is an untold story. When you are sharing something on forum, you should be open, accept the hard fact and explain it clearly black and white. Below youtube link shows how dangerous an EV is, All three vehicles are with LFP chemistry battery only, still its catching fire. Another incident, I am a very big EV enthusiast and I have converted a two wheeler to electric with lithium ion cells, but i am a bit shocked with some of your vehicle pictures, posts and technical details. Hope you understand my concern, great build, Thank you for sharing it. Last edited by SDP : 28th May 2020 at 08:47. Reason: Please restrict the smiley usage to 2 per post. Kindly read the forum rules again. | |||||||
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![]() | #80 | |
BHPian ![]() Join Date: May 2005 Location: Pune
Posts: 190
Thanked: 1,152 Times
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So I will try to answer the questioned / queries, and again, I may be wrong in a few places, apologies for the same in advance, We are enthusiasts trying to create fun vehicles for R&D. 1. Yes We are using the Kirloskar Motor that is also used in the E2O plus However we are trying to produce higher torque with a different controller and parameters. Plus we have the 1st gear for an added mechanical advantage thus amplifying the torque further. 2. 3.35Volts x 16 cells = 13.4 KWh. On Full charge we assume 20% higher voltage thus 14.9 KWh ~ 15 KWh. Please correct me if I'm wrong here. You're right in the range calculations however the weight of our car isn't 1.1 ton, we have tried a lot of things to get the weight of the car down, thus providing a better power to weight ratio. 3. The port provided in the car is only for the regular charger. For fast charging we have to directly connect the batteries manually. Still working on the same. Our next vehicles we are trying to implement CCS Connectors. We have just ordered the necessary hardware for that yesterday itself :P 4. You're right yet again, but the weight factor needs to be adjusted. Also this was by taking the batteries to extreme critical, driving in cold conditions, and with absolutely no power electronics apart from motor controller. 5. Yes we understand reaching 0% is bad, Learning and trying to implement good BMS Solutions. Thanks for your input. 6. SOC is not shown, but is measured. Still need to have it on the display. the BMS Monitors every cell electrically and thermally. Still working on all of this. I don't have a finished product. It's a work in progress. 7. Please don't get me wrong, but there's seriously a lot of work that goes into even fitting bought out components. You'll see the list of things we will be engineering and working upon in the Youtube series that we are launching soon. Starting off with the Maruti 800 build. Will take most of your considerations made here too. For the CAN Network, NO We have not touched the CAN YET. However we are working on it, and again we are still learning, and implementing as and when possible. We take time off our regular work and do this whenever possible. Thanks for your inputs once again. 8. I really believe it is possible, however I also know I have a LOOONNNGGG Way to go before I actually make a Reliable, and Safe Kit like that. But the day will come. When it does, you'll be the first one I Ping ![]() 9. Like Mentioned previously, I'm not a battery expert, thanks for your valuable inputs, I'll research some more on this topic. 10 & 11. I actually have and may be my luck but nothing has happened so far.. I'll take a look into this and do some research. Thanks yet again. 12. Fuses are located not between cells, but on the line from the Cell to the BMS. Incase of a short circuit, the BMS Cuts of the main relay. That's what. I meant by fuses on each battery. And no it cannot stop short circuit between one cell. 13. Still a work in progress, and we wish to disclose that information in the youtube series. 14. I'll take a look into this, thank you for your suggestion. 15. I'm glad you feel EV conversion is simple. I believe we will see more conversions soon from enthusiasts then. Yes regarding safety there are lot of concerns, I am still exploring and learning the same, plus everyone knows batteries are very dangerous and explosive. I just thought there's no need to explain what people probably already know, BUT you have a valid point, I should have mentioned it; will mention it in my further videos. But just because its dangerous doesn't mean we shouldn't explore it right? After all Fuel also was explosive. I know batteries are far more explosive, but at the moment, we do not have an alternate choice. If someone comes up with a safer and better battery, I'll be more than happy to implement it. Plus, I wasn't doing this for money, fame, or even to sell my car in the open market. I was just doing it for Academic purposes and to share my knowledge with others. Such projects cannot be commercialised so easily without proper safety guidelines. A Commercial kit needs to be entirely different. But it all starts with projects and R&D, doesn't it? Im really glad you have built EVs too. It's great to have you onboard, and an honour to have your valuable inputs that can be used on our work further. Good day brother, Take care. Thanks. Mod Note: Please avoid quoting the entire post when responding Last edited by ampere : 26th May 2020 at 06:22. Reason: grammatical error; trimmed quoted post | |
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![]() | #81 |
Newbie Join Date: Jul 2019 Location: HYD/CHN
Posts: 4
Thanked: 2 Times
| ![]() Hi StuntFreak, Kudos, Your thread is out of the Zone. I had been planning and thinking of Converting my car to Electric for some time. This is a great starting point. My Question is, Can we use Iron-Phosphate Batteries for the same. Are they not rugged and safer than the batteries you are using? What would be their main disadvantage? Thanks for making my dream seem possible. |
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![]() | #82 |
BHPian ![]() Join Date: Jul 2013 Location: MH 03 / KL 08
Posts: 758
Thanked: 1,984 Times
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![]() | #83 |
Newbie ![]() Join Date: Oct 2005 Location: Ghaziabad
Posts: 5
Thanked: 0 Times
| ![]() Hi Stunt freak: I am really very impressed with the work that you have done in terms of converting your Beat into an EV. I would Like to get my ALTO k10 2012 model converted into an EV but with a better drive range. Can you please tell me the cost that you would charge to convert it into an EV. Also would you be able to make it an hybrid with a electric motor for low rpms and petrol entgine for higher RPMs. I am based in Ghaziabad and have been looking for converting my ALTO into an EV for long now. Thanks Vineet Last edited by SDP : 28th May 2020 at 08:45. Reason: Removed cell number |
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![]() | #84 | |
BHPian ![]() Join Date: May 2005 Location: Pune
Posts: 190
Thanked: 1,152 Times
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Sorry and thanks. Last edited by SDP : 28th May 2020 at 08:45. Reason: Edited quoted text | |
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![]() | #85 |
BHPian Join Date: Oct 2013 Location: Bangalore
Posts: 28
Thanked: 15 Times
| ![]() Hello Stuntfreak, I came across this Video in YouTube, are you aware of it and has due credit been given? |
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![]() | #86 | |
BHPian ![]() Join Date: May 2005 Location: Pune
Posts: 190
Thanked: 1,152 Times
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Thx Last edited by Rudra Sen : 28th May 2020 at 08:55. Reason: video tag removed from the quote box | |
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![]() | #87 | |
BHPian Join Date: Oct 2013 Location: Bangalore
Posts: 28
Thanked: 15 Times
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Do you want us all to follow the link to the YouTube video and Flag it and report it. Mods: sorry for Digression. | |
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![]() | #88 | |
BHPian ![]() Join Date: May 2005 Location: Pune
Posts: 190
Thanked: 1,152 Times
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Cheers. | |
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![]() | #89 |
Newbie ![]() Join Date: Jan 2020 Location: chennai
Posts: 8
Thanked: 16 Times
| ![]() Hi, you have to check your battery calculation again. This is what I'm trying to explain, when you are making something for academic purpose you should be 100% right. Still don't understand how you are cruising at 100kmph with that small motor on such a heavy car, if you can explain more that would be really helpful. Top speed of e2o plus with 72v system is 86kmph only Even with CCS you cannot charge your 51v battery within 45 minutes Your build is excellent, but your claims are way too high than normal Thanks again, great build ![]() |
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![]() | #90 |
Newbie Join Date: Jul 2019 Location: HYD/CHN
Posts: 4
Thanked: 2 Times
| ![]() Hi StuntFreak, Ever thought about Solar Charging your car, Is it technically possible? How about Inductive charging? Many thanks if you can reply. |
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