» Car DIY »We make from a gasoline car - an electric car

We make from a gasoline car - an electric car



And it is necessary, to convert a gasoline car into an electric one, just a little, replace the ICE engine with an electric one. How Master has dealt with this task, we will learn from this article. He used to do that before car and he has a lot of material on this subject. For those interested, you can watch several videos by clicking on the link. This is not a pure instruction, but rather a direction indicator.

Tools and materials:
-Car;
-Various tools and equipment (wrenches, screwdrivers, drilling machine, etc.);
-Engine from electric lift truck;
-Batteries;
-Coupling;
-Controller;
-Wire;
-Jack;

Step One: Car
The first thing you need to do is choose the right car. They are not all equally suitable for conversion into an electric car. You need something lightweight and energy efficient.

Heavier cars need more energy when driving, and thus, batteries run out faster. Hydro or electric power steering and brakes, power windows and electric locks are also not needed. In general, you need as little power-consuming appliances as possible.

As a result, the master acquired Geo Metro for $ 500. The engine worked fine and the body was in good condition. The clutch did not work, but in an electric car it was not needed, however, like a regular engine.


Step Two: Dismantling
It is necessary to remove everything related to the gasoline internal combustion system. Dismantle: gas tank, exhaust system, muffler, coil, starter, radiator, fuel lines, etc. Removing all unnecessary parts will reduce weight and simplify subsequent installation of equipment. The master did not touch the airbags and other elements of passive and active protection.

If everything is carefully dismantled, then you can sell parts to cover costs. The master bought the car for $ 500, but then sold the engine, gas tank and radiator for $ 550.




Step Three: Adapter Plate
The engine has been dismantled, but the standard gearbox will be used in the future. The question is how to attach the motor to the gearbox? The master found a way out and made an adapter plate from a piece of aluminum sheet. The master took the gearbox out of the car and then outlined it with a pencil and marked all the holes. Then he cut the aluminum plate to the desired size and shape. The center of the drive shaft of the engine and the center of the drive shaft of the transmission should be perfectly aligned.

Before screwing the engine and transmission together with the adapter plate, it is necessary to make a coupling that will connect both shafts.




Step Four: Coupling
You can connect the motor shafts and gearboxes in different ways, but the master decided to use a coupling from some mechanism.


]



With this connection, the car worked all summer. Then there was a breakdown. The master thinks that alignment has not been completely observed. Then the clutch was a little redone.




Step Five: Motor
Master bought his motor for $ 50 at the garage some guy. It was a motor from a forklift. The motor was very old and rusty, but working. The master cleaned it, removed the coils and sprayed insulating epoxy on them, checked the bearings. Also replaced the brushes, put it all together and painted.





Step Six: Batteries
This car uses 6 12V batteries. These are real Deka Dominator helium batteries. They do not require maintenance. The master was able to buy used batteries at $ 12 apiece.

The disadvantage of these batteries is that they are demanding on charging. The master purchased a 72 V charger designed for these batteries for $ 200.

Four batteries are in the trunk of the car, and two are in the front, where the radiator used to be.
For the rear batteries, the master cut two parts of the bed frame so that they lay on the spare wheel and bolted the frame to the frame of the car.

To install the front batteries, the bumper was dismantled. Then the frame is welded and fixed in place of the radiator. Now you need to install the batteries and put the bumper in place.

In the store, the master bought a “charger power input”. This is an electrical connector with a rubber cover. Since the gas tank has already been removed, it has a connector in place of the neck of the gas tank.

Batteries are charged overnight.






Subsequently, the wizard changed the configuration of the batteries. The maximum number of batteries is 12 pieces, which gave the master 144 V. On these batteries, he was able to accelerate to 117 km / h.

He also works on a battery heater in the winter.

Seventh step: controller
The controller is an important part of an electric vehicle. The controller is electronic unit that regulates the operation of the electric motor.

The master uses the Curtis 400 A peak PWM controller, designed for use with series motors. It can operate in the range from 48 to 72V.
The greater the current strength, the better the acceleration (thrust). The higher the voltage, the better the maximum speed and economy of the car.

The 72 V controller proved to be a good compromise in cost and efficiency. Master bought it on E-Bay for $ 300.
To connect, follow the diagrams provided by the controller manufacturer; use thick cables, such as a welding cable, to connect the batteries to the controller and motor.

The master uses a 5 kΩ potentiometer as a choke. The potentiometer is installed in conjunction with the standard gas pedal.

Step Eight: Summary
This car can travel 32 km on a charge, and has a maximum speed of 75 km / h. This is enough for a trip to work and back. If necessary, add batteries.

This project cost the master about $ 1,200, including the purchase of a car. If the master did everything himself, he would have spent only $ 800 on everything. This car is charged in the master’s private home through a renewable energy program. All electricity comes from wind, biogas and other renewable energy sources.

The master mainly drives in third gear, but the engine torque is such that you can start with the fourth.





Heater.
Since this car no longer has the original engine, it also does not have a heater. If necessary, you can install a ceramic heater.

The brakes.
One of the reasons why the master chose this car was that it has manual windows, manual locks, a manual gearbox, and steering without a mechanical drive. The only problem was the brakes. Established brakes have a vacuum booster. With the dismantling of the engine, the brakes do not work as needed.To start, the master played with an aquarium air pump, just to find out how the vacuum brake system works. After that, I started looking for a 12-volt air pump so that it could be used as a vacuum pump. As a result, a 12 V pump and an aluminum cylinder receiver were installed. As soon as the pressure in the cylinder drops, the pump starts to work.

Now the car has power brakes, as it was originally, only it is driven by a tiny electric motor in a small pump, and not a gasoline engine.
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133 commentary
Korolev Well hello, and here the force with which the generator shaft is pressed, it is pressed by a small spring, there is a pressing force of 200 grams. I meant that in addition to the rotation speed of the generator, you must also apply force to it (as part of the rotational generation process). For example, a large generator quickly, do not scroll without applying force, the rotation resistance will dampen your speed, which is limited by the power of your arm muscles. Potential energy -You turned on the spring of the generator on the bike and just let it go downhill, there’s no need for it either, it’s big, it runs off the hill and generates electricity, the output power will depend on the weight of the bike. Well, with a drill, so you take energy from the network, then it’s better to put the power supply, so there are less losses
Nruter
Therefore, they put 2 in parallel and set them in motion simultaneously
Thank you, I understand, otherwise I thought that you were not satisfied with the nominal value of 5 kOhm! yes
Quote: Korolev
Why? As I understand it, the controller controls the potentiometer

Because on one potentiometer, even with its high quality (which I strongly doubt) it is very difficult to ensure 100% contact of the moving element with the track.
Therefore, they put 2 in parallel and set them in motion simultaneously. Although the best option (but also expensive) is to use a pair of encoder --- field effect transistor. Such a pair is now used almost as a volume control in sound reproducing equipment.
With all due respect to the New Standard, I hinted to him that the generator did not give such power and gave my results of the repair of the 2 VAZ generator, measured 1.5 kW.
New Standard
From rotation speed and forces applied on the shaft generator depends
Those. the force with which the shaft is pressed against the wheel! This is a generator mount design, what does your potential energy have to do with it? I will hang it on the wall, spin the wheel with a drill and squeeze the maximum out of the generator! nea
I am engaged in my research work "On the concentration of a magnetic field." I confirm the authorship with a matchbox with a falcon on a fire arrow on a schoolboy’s homemade book.
Korolev It depends on the rotation speed and the force applied to the generator shaft if the generator is well loaded in the magnetic field of its coils (speed on force is power). Potential energy is added here, as the bike rides off the hill (roughly speaking, it falls down). A large inertia (mass) does not allow him to stop quickly, thereby increasing power
Wife at home? My sister accuses me of having not regularly am53.
Once upon a time, I told my wife’s grandmother that if she goes to heaven after death, then her angels will either fly too low or play harps too loudly! ))). But well, she won’t even be there.))) I was offended then. )))).
There are such people.Her (Kingdom of heaven be with her), if they gave something for free - then either little or "poor quality" ....))))
Guest Tim
Just something, gentlemen, no one takes into account the wear of lead batteries when working in this mode. How long will they last? For the same Nissan 10 year battery warranty.
TNT TNT is difficult to obtain in the second stage. Therefore, the Germans when they kapets, switched to other cheap components.
Quote: R555
I wrote that I received pyrocesmin.
Another secret development? Why are you publicly posting the name of the secret explosive ?!
A mosquito has a mass much less than 1 gram. But it suffers from suffering. Refer to the subject of firearms. I shot from different ways, but I came to the conclusion about the kinetic bullet aggnergy.
Valery
So, people will always be unhappy ...))))
Rumor has it that even in paradise there are those who are dissatisfied! They are identified in the fallen angels! smile
New Standard
Well, the more weight the more energy
Energy, generated by the generator, depends on its design and rotor speed, where does your potential kinetic energy, moment of inertia, mosquitoes? scratch
And I remembered how they trash their garbage. The butt is stuffed into a sweatshirt. They didn’t do this to me, but the forest bear was pinned down (if there was one)
A small feature of explosives is that they emit tremendous energy in a small integral time. I wrote that I received pyrocesmin.
PS But hexogen did not work. boss
Or the winding will burn. Get everything back to my ex design with the flywheel from the radio.
New Standard. I'm on the topic of hand-to-hand combat. Hit quickly, precisely, all kinetic energy on the target. You got what I said? I usually don’t kick with my feet, so for finishing off in a fight, but this is not welcome (in public).
Dmitrij Put an electromagnet next to the spark plugs (on the cylinder, drill a groove for it), and glue the neodymium magnet on the piston (also a place for it), and now, voila, the hybrid is ready, you need to make them somehow work synchronously, well or separately when for example there is no gas
I agree that this can affect the power that the generator is capable of delivering. At idle, only revs are important. But, here, if you connect a serious load - a weak weak "drive" just stops.)))))
New Standard
A conventional 5 kΩ potentiometer, yes, it won’t work
Why? As I understand it, the controller controls the potentiometer
The master uses the Curtis 400 A peak PWM controller, designed for use with series motors.
scratch
most likely Porsche has already refused purchase
No, it’s just that Porsch’s batteries are dead, they are charging for them! xaxa
I’m thinking about putting pistons on solenoids xaxa Power can be obtained more than from a fuel assembly explosion. Only in the head you need to bore places under the solenoids. Maybe I'll make a chainsaw motor to start
Korolev Well, how, the greater the weight, the greater the energy, and the mass gives power with speed, like in boxers, why do you think they are divided into separate weight categories? Inertia is also added to the power of the generator (except for my muscular one), and mgh
So, there have been recently.))) The bus station was postponed only this summer.
cars anywhere on the sidewalks are not standing

Cars on the sidewalks are nowhere to be found)))). For us, it’s wild that cars can stand on the sidewalks.I saw this in Odessa a couple of years ago - I was struck by such a mess.)))) We would have brought them to the parking lot with a tow truck ...))))
you still have many bike paths there,
our "bikers" don’t think so!)))) I constantly hear them displeased with the fact that our bike paths are not everywhere laid separately, and often part of the wide sidewalk is simply highlighted under them. They believe that authorities specifically mock them, forcing them to ride on paving slabs, and not on asphalt. (Say, if the bike is tracked, on thin slicks, then this is very problematic.)))
clean, good roads

Well, yes ... We do not have cigarette butts and pieces of paper ... There are enough janitors ... Yes, and somehow they don’t litter too much. You know what I call the “First Bull Effect” is gone. (This is when cigarette butts are lying, you can also throw them nearby. And when it's clean and there are none, you are carrying a half-kilometer goby to the ballot box!)))).
But our people still complain about the roads !. In spring, we are only covered in the central streets, usually. And on minor and in the courtyard territories they simply repair it with “typhoons” .. If you drive fast, such a patch is still audible, although it is only audible, it doesn’t shake the car ... But anyway, people who don’t know the other are yelling “Roads killed !! ! Shame! "... I told them that in the same Ukraine, for example, I saw the pits UNFILLED !!! And, not only in the city, but also on the highway !!!
Do not believe! (We have a "road with holes" - this is a roadway with patches rolled up by "Typhoon"). They say that this cannot be, because then the road builders would go broke buying new wheels !! Modern youth are very fond of sharpening "how they are offended." If there was a pit not completed in the city, there would definitely be those who "the nose froze to evil mom", would fly over it at speed, would break the wheel and call the traffic police to draw up a protocol on the road workers, and then scream in YouTube, everything is bad ...
So, people will always be unhappy ...))))
And the fact that you like Brest is nice. Come for a visit. We will be glad.
New Standard
The fact is that a "weighty" bike has a lot of inertia ... potential energy = mgh
I do not understand how this affects the power generated by the generator? dontknow
Nruter A conventional 5 kΩ potentiometer, yes, it won’t work Dmitrij I’m probably remaking my car for electric traction, I probably already refused Porsche’s purchase, since it’s developing a powerful “Liquid rheostat (experiment)” to regulate the speed of the electric motor
Korolev An interesting question, I think, and Valery will give his opinion. The fact is that a "weighty" bike has a lot of inertia. Here is a vivid example for you: is it easier to stop a mosquito flying at a speed of 70 km / h, weighing 1 g, or stop a mass of 130 kg at a speed of 70 km / h? Which also comes from the mountain with acceleration, potential energy = mgh
Valery I like Sovetskaya Street in Brest, and the fact that it is completely pedestrian, you still have a lot of bike paths, a beautiful bus station was built, it was moved a bit from another place (it used to be the old one who was killed), and right now it's super modern, clean, good roads, cars anywhere don't stand on the sidewalks
I realized my childhood dream of stealing gas from a machine with triple syrup.
A man fulfilled his childhood dream, apparently.
And in itself his electric car is complete nonsense. From the clutch to the invented brakes. So just ride around the yard, entertain the kids. No more.
I was especially surprised by the 5 kΩ potentiometer for adjusting the speed of movement. By the way, 2 potentiometers are installed in electronic pedals on cars at once.
New Standard You correctly understood that the winding loses its efficiency during nagev.
New Standard
a bike with a cyclist weighs 130 kg
I’m embarrassed to ask, but don’t the generator care about the weight of the cyclist? I thought he only needed revs ... scratch
New Standard, I live in Voronezh, I have no order to strike at my own people, who helped to win the Second World War
P.S. When is Brest City Day, it seems to him for 1000 years? Want to congratulate
Yesterday!!! Thanks! ))))
I'll try to count tomorrow. Yesterday we walked all day ... At 23.00 there was a festive fireworks display. Until returned from him - half past five. A little more "celebrated" with kmoviyami ...
Today is again a continuation of the banquet.)))
it seems to him for 1000 years

Yes. Although, in fact, not “him,” but his prototype .... After the partition of the Polish-Lithuanian Commonwealth, the Russians demolished the city and built the Brest Fortress in its place to gain a foothold in these territories ... Citizens lined up a bit to the side. So, really our city is one and a half centuries of everything! )))) ... Although ... Almost two already ..
Valery I don’t weigh more than a centner, it’s better to help calculate the power, the people are interested, but without you nothing. In the data: a bicycle with a cyclist weighs 130 kg, travels at a speed of 70 km / h (19.5 m / s), a generator that stands on a wheel can use only 30% of that power. What power does the generator give out?
P.S. When is Brest City Day, it seems to him for 1000 years? Want to congratulate
R555 Resistance is increasing, but I do not argue. You said that it is necessary to measure both current and voltage at the same time, not to be mistaken? The resistance of the ammeter is zero, if I measure them at the same time, then the ammeter shunt will burn, and the voltmeter will not even have a chance to “pop”. On the generator winding, I measured "either" the voltage (first, to measure the current and subsequent burnout), "or" the current at the same generator speeds. There, even the magnet from overheating is clearly “exploded” not to mention the winding. The resistance of the winding, but it fused and then burned out, it is just impossible to measure the resistance there in the cold state, except to rewind a burned-in winding, measuring the diameter, to count how much it was. You did not consider the power (30% energy use) 130 kg is great which travels at a speed of 19.5 m / s, huh?
New Standard. I muddied a new topic on magnets, how to use to relieve people from pain by pulling out drunk small wires with a narrowly directional concentrated magnetic field
Mopeds are much lighter. Although ... Maybe there is a cyclist more than a centner?)))))
New Standard, I'm in shock. No, well, if you were not mistaken in measuring the voltage and current of the generator, the power is really not weak. Is there a way ohmmeter? I'm interested in the resistance of the winding of your bicycle generator. in a cold state, because when the winding heats up, and it heats up very quickly, its resistance is .... tsya. Why am I?
Ivan_Pokhmelev There are just a lot of equipment for AKM)) (just kidding), this one, the battery is about 20 kg, I’m also a generator, 8 l water (I took it for weight), and so little things: keys, spare parts. Yes, of course the weight is with me!
Ivan_Pokhmelev
Some kind of monster. Almost as light as a motorcycle
I think this is with a cyclist, someone should pedal! smile
Quote: New Standard
what power a bicycle develops, its weight in equipment is 130 kg

Some kind of monster. Almost like a light motorcycle weighs.
R555 I do not agree with you that only 15 watts. A small cycle generator of 6 V, 3 W (according to the passport) at a bike speed of 70 km / h makes about 320 revolutions per second (320 Hz), while giving 74 V and 4.2 A, this is 310 W. At the same time, it is almost not felt, only when the amperes dampen the speed very much, it makes a lot of noise and heats up, one already burned so the plastic plug melted and the magnet collapsed and fell off. Here, calculate how much power a bicycle develops, its weight in equipment is 130 kg, and rushes off a hill at a speed of 70 km / h, well, what? Well, even if not all that power can be taken away by a generator, but only say 25-30%, the figure is still large. Watt is: Nm / s, I repeat the speed is great about 19.5 m / s (70 km / h), weight 130 kg.
New Standard. Glad your enthusiasm. But 500 watts is unlikely. Not so long ago, I immediately repaired 2 VAZ generators (for the sixth model). They checked with a friend in a car. I indirectly tried to determine the power of these generators. It turned out, somewhere around 1.5 kW. I did not look at their passport data, how many new ones should be there. Well, with the generator on the bike from the mountain ... Watt 15, I think, no more. The measurement scheme is the simplest. Ammeter in the gap of one of the wires, parallel to the load of the voltmeter. By multiplying the readings, we determine the power. That's just how to read these readings on the go, remember and write down and not fall down with the great at the same time. You can do only with a voltmeter, if the load resistance is known.
R555 Fun if read with AKM)). Yes, there was a battery on the trunk, and the generator also connected with a strong acceleration from the mountain, then the power was not small, it definitely did not measure, probably above 500 W
New Standard
Yes, no, battery, typo
Yes, I realized that a typo, but still more fun
great with AKM
good
New Standard, but where was the AKM, behind or on the shoulder? Or confined to the great? Okay, once confused with the battery, but three times in one message ...
New Standard, since you remembered the cartoon with squirrels, I also remembered the cartoon from the Kievnauchfilm studio or Odessa Film Studio, I don’t remember exactly the Adventures of Captain Vrungel. So in it, Captain Vrungel placed the squirrels saved in the fire in a huge wheel on his yacht and overtook competitors in a round-the-world sailing regatta. Have you watched this cartoon? The cartoon, it seems, is for children, though it is clearly shown there are clearly not children's things. Some characters constantly smoke, drink, play cards, and in a case from under the double bass they smuggle a naked woman, or rather a statue stolen from the museum.
Korolev Yes, no, battery, typo, but AKM can also be recharged))

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