EV CONVERSION MAYOR COMPONENTS AND PARTS

Jomel Maldonado Adrin Bagu Jos M. Cruz

Advisors Awilda Melndez Edgardo Desardn

Donor vehicle
The proposed donor vehicle is a 2010 Ford Ranger or

similar, with an approximate curb weight of 3120 pounds before the conversion. A rough estimate of 500 pounds will be reduced once the internal combustion engine, radiator, fuel system, fuel tank, exhaust system and associated parts will be removed for the conversion. The automatic transmission should be changed to a manual transmission to reduce dissipation of power from the electric motor and increase the range of miles between charges. The manual transmission will have the original clutch and all 5 speeds available.

Donor vehicle
The supplemental restraint system, air bags and Antilock

Braking System will remain functional to comply with NHTSA, DOT and other regulatory agencies. All other functions like Wipers, Horn, Seat Belts, Lights and Signals will remain operable to comply with the DOT agency and to be certified as a road worthy vehicle. The CAN Bus communication will remain operable, thus the instrument cluster will remain functional. Power steering and power brakes will remain as effective as the original vehicle configuration. The total weight after the conversion is estimated to be 3800 pounds. The estimated range between each charge is 45 miles if driven at a conservative 40 MPH. The estimated energy consumption is 385-500 watts-hour/mile.

Manual Transmission

Since the automatic transmission dissipates a lot of

energy in the form of friction, heat loss, rotational inertia and viscous coupling, it will be replaced with a 5 speed manual transmission for better drive train efficiency. The replaced transmission should be from a Ford Ranger with a 4 cylinder, 2.3 liter engine since it has optimal gear ratios for the electric motor.

Electric Motor

Warp 9 inch series wound DC motor, double ended shaft Continuous Ratting = 28.8 HP / 70 lb-ft @ 72V/334.5A Peak Ratting = 70 HP / 143 lb-ft @ 120V/435A Max. Efficiency = 89.1

Electric Motor

Electric Motor

Adapter Plate

An adapter plat will be used to couple the Warp 9 electric

motor to the manual transmission; it will retain use of the original clutch. A customized aluminum coupler will mate the electric motors shaft to the manual transmission clutch. In order to achieve reverse operation of the drive train, the mechanical gears will be used, thus eliminating the need of typical H-Bridge electrical configuration; this will simplify the circuit and reduce voltage drop.

Controller

Warp P Drive controller with Pulse Width Modulation capable of

managing up to 1000 Amps of current at 170 volts maximum input voltage. The approximate weight is 16 pounds.
Additional options that can be upgraded: Cruise Control Tachometer Input Battery Management Digital display output via CAN Bus communication

Pedal Sensor

Used with the WarP-Drive Controller, Dual Hall Effect

sensors are used, to produce a signal that does not deteriorate over time and use. Based on the Toyota Prius Pedal sensor.

Interface Module

Digital display connected with the controller output via CAN

Bus communication for the following parameters:

Motor Amps and Volts , Battery Amps and Volts 2) Controller Temperature, Throttle Position 3) Error and warning codes
1) All internal sensors and displayed parameters can be saved for

data logging in a Mini SD Card.

Traction Battery

A total of 45 Thunder Sky LiFeYPO4 Batteries will be

connected in series; each battery produces 3.2 volts and has an amp hour capacity of 200 amps at a 20 hour discharge rate. The total voltage will be 144 volts with an available power of 28.8 kW. Each battery weights 16.10 pounds, which will increase the vehicles weight to an additional 724 pounds.

Charger

To recharge the traction batteries, a solid state 3 kW high

frequency charger will be employed. This charger has an input of 120-230 VAC and a programmed output of 24144VDC @ 16-80A The power factor is at 98%.

DC-DC Converter

A solid state DC-DC converter will charge the auxiliary

battery (12 volts) with the traction batteries (144 volts). It has an input of 100-200 VDC and an output of 14VDC @ 60 amps.

Power Brake

An electric vacuum pump with a reservoir will substitute

the original vacuum source that was obtained from the internal combustion engine. This will assure the safe operation of the power brake system.

Power Steering

An electric motor will drive a mechanical pump to keep

the original power steering assist of the vehicle.

J1772 Charging Connectors

The J1772 Adapter box is used to connect a J1772

Charging Station, EVSE, to a NEMA receptacle. The Adapter Box contains a pilot signal generator that enables the 220 Volts AC in the EVSE.

Resources
Name Responsability

Jomel Maldonado
Adrian Bagu Jos M. Cruz

Team lead and Electrical Design lead

Mechanical design lead Welding design lead

Estimated Budget
Description Components and Materials Student Wages Faculty Wages
* Estimated amounts A Flooded Lead Acid Batteries B Lithium-Ion Batteries

Amount* $17,200.00A or $25,800.00B $6,000.00 $4,000.00

Questions