Driving to Net Zero with Full Performance


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Conversion of a 2003 BMW 325i to an electric vehicle with equal or better performance to the original gas powered specifications.

By Bob Simpson of EVDrive.com

Published in: Automotive
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Driving to Net Zero with Full Performance

  1. 1. Driving to Net Zero with full performance<br />
  2. 2. Project goals<br /><ul><li>Make an electric commuter for daily use, 40 mile round trip
  3. 3. Choose a fun and competent sports car platform
  4. 4. Meet or exceed original performance
  5. 5. Match the annual energy consumed with grid tied solar array</li></li></ul><li>Design philosophy<br />Start with an excellent ICE design<br />Replace ICE drive with equal or greater performance electric drive<br />Match the weight and its distribution<br />Gain confidence in battery cells from a focused study and gathering real data <br />
  6. 6. Warm up projects<br />A fun battery test and development platform<br />This served as my BMS and cell packaging trainer<br />
  7. 7. University of Vermont hybrid electric race car<br />
  8. 8. Oregon State university Solar vehicle<br />
  9. 9. The chosen platform<br />2003 BMW 325i<br />
  10. 10. Commitment time<br />A young motor about to be pulled<br />
  11. 11. Brother Randy assisting with the removal<br />
  12. 12. The hanging ICE is destined for craigslist,<br />The BMW is destined for transformation<br />
  13. 13. High Tech modeling process:<br />Motor and Inverter forms<br />
  14. 14. 2040 cell Lithium Ion Battery pack<br />Cells = A123 systems<br />
  15. 15. Motor comparison<br />Before and after<br />
  16. 16. New Drive package<br />Siemens AC induction motor<br /> mated with original 5 speed transmission<br />
  17. 17. Installing new drive<br />The motor installation is now a simple, one person job<br />
  18. 18. Inverter <br />Blue unit is a 700V 100kW drive (134 HP)<br />150kW drive Inverter going in soon (200 HP)<br />
  19. 19. 15kWhr Battery pack<br /> This 700 Volt pack can deliver 1200 amps peak (10sec).Peak demand from 100kW drive system is 13% of that.<br />
  20. 20. Bottom of pack<br />Primarily for heating in winter, this plumbing uniformly distributes the heat.<br />
  21. 21. With plumbing secured <br />
  22. 22. Inside the pack<br />Modular format makes for easy access and low/safe voltages when handling<br />
  23. 23. Inside the pack<br />1 of 30 modules<br />
  24. 24. Inside the Battery pack<br />Plugging in the BMS slave boards<br />
  25. 25. The Result<br />Fun, Fast and efficient<br />The range is currently 45 miles, soon to be doubled<br />I have 6000 miles logged as of March 2011<br />
  26. 26. Waveform data of my drive to work<br />700V --><br />650V --><br />Acceleration Current<br />0 A --><br />Regen Current<br />Yellow trace is pack Voltage<br />Blue trace is pack Current<br />
  27. 27. Power profile of my drive to work<br />Average Freeway <br />Power <br />(16kW)<br />This shows the true power being consumed over 20 mile commute<br />
  28. 28. Other conversion benefits<br /><ul><li>Full regenerative braking with high percentage energy capture
  29. 29. One moving part in motor. No service other than tires and wiper blades
  30. 30. Can be driven as original Manual transmission intended OR Automatic
  31. 31. On-board charger can plug into any power source, just carry plug adaptors
  32. 32. Daily commute costs are 4.7 times less than ICE equivalent at $3.50/gal</li></li></ul><li>Solar array preparations<br />The Christmas tree farm gone wild…<br />Started with 70% exposure, need to meet or exceed 75% for grant money.<br />We sent the logs to the local mill with proceeds helping fund the array.<br />5.5kW Array soon to be installed will match annual BMW driving energy. <br />The Blue roof is the planned site for the array, laying flat on surface.<br />
  33. 33. For more detail on this and other projects<br />www.evdrive.com<br />