Backgrounder on my home project converting a 1997 BMW 318ti to electric

1. A Quick Look at the Road Ahead
and Life with an Electric Car
Phillip Crippen


2. Agenda
Introduction
Choices
Range Anxiety
Upgrade Options
The Outlook
2

3. 3
A. B.Food Cave
Goods Market
Me Anywhere

4. 4
Energy
Storage
Prime
Mover
Vessel

5. Build: e318ti
Donor: 1997 BMW 318ti, 207k miles, purchased Oct 2008
Factory Converted
Engine 4cyl 1.9l 9inch DC
Max HP 103 HP @
6000RPM
100HP @
5000RPM
Max Torque 133 ft-lb @
4300RPM
115 @ 500A ,
0-5000RPM
Max RPM 6500 5000
Top Speed 140mph 80mph [108?]
Curb Weight 2950 lbs 3100 lbs
5

6. Build: What Comes Out?
Lots of Greasy, Dirty Stuff
Radiator
Engine (!)
Exhaust
Gas Tank
Heater Core
Power Steering
Brake Boost
6

7. Build: What Goes In?
Cleaner, Drier Stuff
Motor
Controller
Batteries
Electric Heater
Elect. PS Pump
Vacuum Pump
7

8. Build: What’s Going on Under the Hood?
Two Layers under the Hood: Controls and Action
Controller
Batteries
“Gas Pedal”
Motor
Elect. PS Pump
Vacuum Pump
8

9. Build: What About the Other End?
Batteries and On-Board Charger
Charger
Batteries
9

10. Controller
B+ B-
M-A2
1 2 3
A
318ti Conversion
Crippen
Page 1 of 1
Power and Control
Schematic
Created on
Revision 3
8/15/09
Date
9/21/09
Date
CR+ CR-C1+ C1-
V
BC1
PF1
300A
From
Potbox
Main Drive
C2-C2+
K3
87 30
K2
+
A1
A2
S1
S2
12V
From
PS1
Aux Batt
Donor Key
Donor 12V
Bus
K1+
K3
85 86
K2+
Potbox
Com
Wh
Bk
NO
NC
To
Drive
+
Controller Fan
Vacuum
Pump
Vacuum
Switch
Gnd
L2 T2
115VAC
144 VDC
Rear Battery Box
CF2
2A
IS1
Donor Heat
K4+
PS Pump
C1 A2
K5+
K5
<10> <10>
<10> <10>
<10> <10>
<10>
<10>
<2/0>
<2/0> <2/0>
<2/0><2/0>
<2/0>
<2/0>
<12> <12>
<12> <12>
<12>
<12>
<12>
<14> <14> <14> <14>
<14> <14>
<14><14>
<14> <14>
<14> <14> <14>
<14> <14> <14>
<14>
<14>
<14>
R BK
R R
R
R
Y Y
Y
R
Y Y
Y
R BK
R
R R R
R
R
R
R
R
R
R
R
RR
R
BK
BK
BK
BK
BK
BK
BK
BK
BK
Heater
K4
CF1
20A <12> <12> <12>
Y Y Y
PS1
+
-+
-
12V To
Controls
KLK
Y Y
K1
+
<12> <12>
C3-C3-C3+C3+
B5
A1
Schematic

11. Agenda
Introduction
Choices
Range Anxiety
Upgrade Options
The Outlook
1
11

12. DC vs AC
DC AC
Motor
Complexity
Brushes & Commutator
for Wound Rotor
Rotor cast, no rotating
wiring
Controller
Complexity
Simple (PWM) Voltage
Control.
Regen Complex
Complex, chopping DC
into AC waves.
Default Regen
Torque ~Current ~Deviation from rated
speed
Speed ~Voltage ~Frequency
EV Setup Cost Low High (2x)
Typical EV Voltage 144VDC 360VAC
Battery Pack 12x12V 30x12V
12

13. Battery Alternatives
Type Advantage Disadvantage
Lead Acid Cheap, Available Heavy, Lowest Energy Density
Flooded Cheapest Frequent Maintenance
Sealed Flooded Lower Maintenance Sensitive to abuse
Gel or AGM No Maintenance, Safe,
Flexible Positioning
Pricey, Shorter lifecycle if abused
Nickel Metal
Hydride
Longer Lifecycle, higher
energy density
Significantly more expensive, Battery
Management system required
Lithium Polymer Highest energy density, quick
charging, flexible packaging
Most expensive, battery management
system required
13

14. 14

15. Agenda
Introduction
Choices
Range Anxiety
Upgrade Options
The Outlook
15

16. 16
Creative Routing
Elevation

17. Speed & Aerodynamic Drag
• Slower driving leads to extended range
• Drag increases at the cube of velocity
17

18. Charging Options
• Level 1: Home, Public
• 120V, 15A
• 8-12 hrs
• Opportunity Charge
• Level 2: Home, Public
• 240V, 30A
• 4-6 hrs
• Level 3: Station
• 240 or 480V 3Ph, 80A
• 30 min
18

19. Charging Options, A Different Approach
• Better Place
• Shai Agassi
• Partnered with Renault
• Company owns Battery
• Traditional “Station”
paradigm
• Trials in
“Economic Islands”
• Hawaii
• Israel
• Denmark
19

20. Ever-Growing Infrastructure
20
www.plugshare.com

21. Hydrogen Fuel Cell Vehicles
++=

22. Hydrogen Fuel Cell Vehicles
• Where does Industrial Hydrogen Come from?
• Natural Gas (methane) Reformation:
CH4 + H2O (+ heat) → CO + 3H2
++=

23. Agenda
Introduction
Choices
Range Anxiety
Upgrade Options
The Outlook
23

24. Project Phasing
Life Imitates Work
Phase 1 Phase 2 Phase 3
Functional EV Reliable EV Enhanced EV
Started Jan 09 Started May 10 TBD
Complete Mar 10 Complete Aug 10 Budget Constrained
Drivetrain & Safety
Systems complete
Power Steering, Interior,
Clutch, Detail job, Basic
Data Logging
LiFePo4 batteries, recalibrate
suspension
“Der Weg is das Ziel”
24

25. Upgrade Options
25
Upgrade Type Characteristic Effect Benefit
LiFePO4 Higher Energy
Density,
Lower Weight for
same Storage
300 lbs less than 100Ah
AGM pack
Deeper
Discharge
80% of Rated
Capacity
30% 80Ah (4.3KWh)
practical capacity
increase
Faster Charge
Rate
1 hour reduction
@220V
Improved flexibility
10x Charge
Cycle Life
(~2000)
Compare to cost of
10 AGM packs
High one time costs, but
less frequent
replacement
Low Rolling
Resistance Tires
Change in
Compounds,
Profile
Reduced Rolling
Resistance
Improvement may be
offset by initial cost
AC Drive Regenerative
Braking
Drive permits
reverse current
flow
40% energy return
Lower Motor
Maint
Brushless rotor Lower friction loss, 4%
more efficient

26. Agenda
Introduction
Choices
Range Anxiety
Upgrade Options
The Outlook
26

27. Concerns and Roadblocks
• How “Green” are Electric Vehicles
• Manufacturing Industry Inertia
• Battery Pack Performance & Cost
27

28. Common EV Myths
• It’s easier to put scrubbers on power plant smoke stacks
than to control millions of tailpipes (Only 52% of US
electricity is generated using coal-2010)
• EVs are inherently more efficient at converting stored
energy to motion. Electric motors have efficiencies of
up to 98% while an average Internal Combustion
Engine (ICE) is only 18-20% efficient
“EVs create more pollution by using electricity from
coal-fired generation plants”
28
Update: as of 2015, Coal fired electricity
down to 33% with Natural Gas also at 33%

29. Manufacturing Industry Inertia
• Not enough demand for OEMs to support
• Huge transition in Mfg Asset base
29

30. Common EV Myths
• Advanced Battery Management Systems minimize
damage from extreme use events
• Improvements in Li-Ion production techniques and
chemistry increase production yield and reliability
• Today’s Lead-Acid battery ecosystem recycles 97% of
material in the automotive fleet’s batteries. Similar
reprocessing techniques are in development for
advanced chemistries
• EVs place extreme performance demands on batteries.
A secondary market is developing for “retired” battery
packs with less severe requirements (UPS, Grid
Stabilization)
“Battery packs don’t last long enough and are
expensive to replace”
30

31. Where else are PEVs in use?
LAX
Indoor GoKart track
Rogers AR
31

32. Was it Worth It?
• Gas Cost vs. Initial Conversion and Ongoing Electricity?
Not even Close
• Pollution, Reducing reliance on Petroleum?
~It Depends
• Experience, Opportunity to Share with others?
Absolutely!
32

33. 33
Epilogue
May 21, 2015
Sold to a Good Home in
Baton Rouge Louisiana

34. 1996 Ford Ranger

35. 1996 Ford Ranger

36. Q&A
1
36