How we made electric car 2

And here it is, the sequel...

We drove the first car for two seasons (now it is gathering dust in the garage). At first she seemed so beautiful, but now, having soberly assessed her appearance, we are horrified. The son has grown up, his view of the aesthetic side of the car has changed, maybe there are other reasons, but car-1 was no longer suitable, but I want to ride ... As usual, my parents have no money (no, we are not greedy, just prices have risen again). In short, it's time to make a car-2.

There were several nuances:
1. The car should be as large and powerful as possible and at the same time enter an ordinary elevator, pass through the doors of an ordinary apartment and be light.
2. Consume little energy.
3. To be beautiful.
4. Other incompatible requirements.
5. The total power of the engines is not less than 180 watts.
6. Having the experience of car-1, it was decided that the brakes are MANDATORY.
7. Smooth "gas", i.e. I needed an electronic motor control circuit.
8. The wheels are inflatable.

Wheels were purchased first. Wheels from a conventional garden cart. Selected for appearance, size and WEIGHT. I was on the market today and bought wheels for a car with a diameter - 350 mm width - 80 mm weight - about 600 grams one (that is, surprisingly light ... which is what you need) two bearings. For 4 pieces they asked for 2000 rubles .... they gave it for 1800 ... well, there are simply no words ..... and this green creature (in the sense of a toad) .... Oh. The larger the children, the more expensive the toys. Now, about the sad things, I opened the wheels (which I bought for 450 rubles a piece), looked at the bearings ..... There are no words from indignation, a huge backlash, low-quality iron (you can make a deep scratch with an ordinary nail), they make noise when driving .... it sucks , and not bearings, you will have to spend money and buy 8 new bearings .... And this is an additional 250 rubles. Yes, Chinese bearings are ..... well, in short, I did not expect this. I bought 8 bearings 204 for wheels, 4 - 101 for suspension, 3 - 100 for brakes - I gave 290 rubles in total. The bearings are satisfied - there is no backlash and they are not scratched with a nail. Then the engines were selected. Considering all the accumulated knowledge and the environment in the field of availability of engines on the market, we settled on the engines of the cooling system from a passenger car.

250 watt (very tempting in terms of power) from UAZ or Volga did not fit for two reasons. 1. expensive (1000 rubles a piece). 2. current consumption is quite large.

There were 110 watts from the VAZ, they were then bought for 450 rubles. per piece

After buying the engines, the question became, how will the torque be transmitted to the wheels?

After numerous experiments, it was decided that with a rubber band cut out from the chamber of a car. And therefore, pulleys for the wheels and for the engine would have been ordered from the turner at the factory. According to the drawing I gave. pulleys.

I want to warn those who will repeat my deeds. As it turned out, for a flat-belt transmission, BARRELS-SHAPED pulleys are needed, otherwise the belt crawls out from the pulleys ... I didn’t want to redo anything, and I wasn’t going to and got out of this situation by cutting one wide belt into 4 thin

What to do with the engine speed control? I ordered the Dimmer for incandescent lamps 12 V / 50 A - NM4511 ... they asked for 250 rubles. Promised to bring within two weeks maximum.

This regulator works in pulse mode, exactly the same mode on screwdrivers. Got a motor control kit.
first impressions - And this snot will drive 600 watt motors???
Until I do it and I'm not convinced - I will not believe it.

The scheme of the whole car was modified for use as an engine regulator, some elements were added. The power transistor was planted on the radiator from the processor.

Steering wheel….needed a small steering wheel…where can I get it?
All sorts of thoughts thought, but I had to go to the car market fork out 500 rubles. on a real sports steering wheel from a real car.

Now about the important thing - the brakes. at first we thought about disc ones from bicycles, but their price is 1400 for one set ... otherwise it would be generally gorgeous
I had to look for a cheaper option ... and it was seen on a factory 4-wheel adult bike - the wheels are braked by simply pressing the bar to the rubber of the wheel from above.

Now we need to buy plywood, more bolts, radio components, sensors ... well, there is still a lot of small things ... And you won’t find some in our city at all - you have to order it. Weld the pedals ..., buy paints, work, horror in short.

But then you can already cook the frame!

Put and slowly collect the car ...

The electrical circuit has also been given more than one day ...

After sawing off the excess and processing it with a file, they took it to the garage ...

We are already in the garage (the mother of the children kicked out of the house so that they do not stink of paint) we are priming the car. It remains to pull the pieces of rubber hose on the bumper (dear dog)

and install a bike computer (shows speed, distance traveled .... and a bunch of all sorts of data ... wheel size is adjustable, so it shows quite accurately),

and put the battery 75 A / h.,

and creation - machine-2 is ready!

Sometimes my son and I ride it together - that is. load under 100 kg.

So let's take a step-by-step look at the work done.
The guys from Lithuania took the old VAZ-2106, even demonstrated that it works - they installed the battery and started the engine internal combustion.

Most likely, the guys used the prototype as an example - .

In principle, a pretty good choice of car, the VAZ 2106 is a fairly light car. At the same time, the car is not the smallest in terms of body size with large offsets relative to the axis of the wheels in front and behind. Quite a lot of space at the vaz-a engine compartment and in the trunk - it was there that the masters installed a whole battery of batteries.

Let's get back to the engine. As far as can be judged from the video, they decided to use an engine for the electric drive direct current with a power of 12 kW, most likely with a supply voltage of 110 volts. In appearance, it can be assumed that similar engines are used in electric cars or industrial devices.

12 kW converted to approximately 17 hp - which most likely does not promise great dynamics assembled car. However, I would like to note that the internal combustion engine, which in fact makes up 80 percent of the car's weight, was dismantled from the car. On my own body vaz-a not heavy.

I would like to note one not very positive moment - the guys decided to use their own manual transmission VAZ. It is not known whether they had to redo some of the design features of the gearbox (say, remove the synchronizers), but on the video you can clearly see that the gears are switched without connecting and disengaging the clutch.

A very bad moment was noticeable when one of the authors touches the gearbox shaft with his foot and cannot stop it in different gears. Then the neutral gear is switched on and the shaft is still spinning. At the same time, a rather distinct noise is heard and the shaft continues to rotate, although with a little effort it can be stopped.

This all suggests that the box is not in better condition, most likely there will be quite large losses in it. Considering that the box itself will add weight to the car, as well as its gear ratios in principle, they are not very relevant when using an electric motor (the torque at different revolutions of the engine is almost the same) - it is possible to use the native box was not the best solution.

Although the box with the clutch unit made the installation process much easier.
As far as we could understand from the video, the guys welded the clutch disc to the axis of the electric motor, and also welded a frame from a corner for mounting the engine in the engine compartment.

A frame was assembled and welded from the same corner, with the help of which the clutch disc on the electric motor was connected to the clutch disc on the gearbox.
In the course of the entire video, it was not possible to understand whether the creators use this clutch for its intended purpose - most likely not.

One of the authors shows us after the assembly how the car itself drives into the garage. Most likely, only a regular battery is used for recharge, and it is enough for the car to drive back into the garage by itself. You can even see sparks flying when the motor is connected directly to the battery.

Now, in order to control this mighty beast, it was necessary to assemble a strong power controller. The test was carried out from a voltage of 24 Volts (2 batteries of 12 Volts). The only thing that can be seen on the video is that some kind of microcontroller and several field effect transistors were most likely used (there are only 3 of them in the 24 Volt circuit). Most likely, the field workers do not get very hot, since the authors of the video boldly touch the radiators with their hands when the electric motor is running.

The final videos show how the car works, including on the track.

Here you can clearly see how the car looks after a full assembly cycle. In pretty big trunk The authors installed 5 batteries. It is noticeable that a switch is immediately installed for emergency disconnection of all batteries from the trunk, perhaps a current fuse is installed nearby, or maybe this is an automatic relay that closes the contacts when the system starts. In general, there are any decisions that are essentially very important for the safe use of such powerful electrical systems, and at the same time functionally the essence of the process does not change.
Immediately in the trunk, we can notice the lack of a spare tire - a very correct solution to lighten the car.

Three more batteries are installed in the engine compartment. As we discussed above, in the engine compartment, the VAZ has a lot of space, if, on top of everything, we take into account that the engine used in this design is quite small compared to an internal combustion engine.

A very correct decision would be to arrange the batteries in the front and rear parts evenly, this will have a very positive effect on the weight distribution of the car, which means its stability on the road - handling.

The new 96 volt control box now looks completely different. It is assembled in a beautiful shiny aluminum case, and thoughts are already creeping in that it can even be factory-made. Right there, next to the control unit, a regular battery was hidden to power the on-board network of the car. Now, to charge it, you also need a voltage converter and it probably lies in the same box of the control unit.

Power batteries are much larger than regular ones. It can be assumed that most likely these are serviced traction batteries (plugs are visible on each section, battery cell).

We also managed to find the official website of the battery manufacturer SIAP http://www.siap.pl/firma.html - the company is specifically engaged in the production of traction batteries, unfortunately it is not described what type (most likely they are lead-acid).

Total battery capacity 110 Ah
Operating voltage 96 Volts
At the same time, as we remember, the motor power is 12000 watts

That is, each battery at a voltage of 12 volts produces 100 amperes per load - approximately equivalent to 1200 watts. Quite acceptable values, given that such currents will only flow at full load. Most likely, the batteries do not even heat up with uniform movement and work in a stable mode.

In the video where the car stops and starts again at a traffic light, you can see that the current strength reaches 178 Amperes (178 A * 96 Volts = 17080 Watts). This is even more than the rated power of the engine. By the way, I would like to note that many motors can operate in short-term overload modes up to double the rated power.

As a result, according to the assurances of the authors, the VAZ 2106 electric car can
- it is charged from a network of 220 Volts within 7-8 hours
- on a full charge covers 50-60 km
- maximum speed 70 km/h (in the video you can only see a demonstration of movement at a speed of 40 km/h)

Will anyone be able to repeat the experience of such talented masters. Or maybe these cars will finally be put into production?

Do-it-yourself electric car for a child: photo and description of a homemade product.

Craftsman Anton from Vladivostok made an electric car for his little daughter with his own hands, we invite you to take a look detailed photo report on the construction of a homemade children's electric car.

Materials used:

• Electric motor from Toyota wipers.
• The sprockets are made from a 3SFE pump pulley and a 5AFE crankshaft pulley.
• Belt from Subaru Forester, (it had to be shortened twice and glued-stitched).
• Motorcycle battery - 12V 9Ah 45A.
• Wheels from the cart (diameter 210 mm).
• profile pipe.
• Textolite.
• fasteners.

The seat is made as follows. Made a template out of cardboard. I bought a jar of resin 800 gr 650 rubles and two packs of fiberglass 150 rubles * 2 pieces, and stuck it on a template that was already ready and glued with adhesive tape, the work took about a week. Then he puttied, sanded, primed and covered in leatherette, of course, placing 10 mm foam rubber.

The steering wheel is made of plywood.

I fixed the electric motor, installed the stars and the belt.

Steering. The cardan shaft was optimally suited from the Toyota Probox NCP50, and the stabilizer links, which act as a tie rod with tips, were made from Toyota Voxy AZR60 nodes.

I cut off the pedal from the car and welded to it a swivel nut that acts as a bearing, and a stroke limiter. I welded a return spring to the frame. under the pedal, I installed a microswitch for supplying current to the electric motor.

Installed a toggle switch that changes the polarity of the current so that the car can move back and forth depending on the selected gear.

Modern realities are such that more and more motorists are trying to switch to easy-to-use electric vehicles. Unfortunately, despite the many advantages of such an alternative to vehicles with an internal combustion engine, not everyone can buy an electric car because of its high cost. That is why many craftsmen have already begun to convert cars into electric cars with their own hands. Such an event is much cheaper than the purchase of ready-made vehicles, but it has several disadvantages. Therefore, before you start reorganizing the innards of your four-wheeled friend and turn it into a full-fledged electric car, it is worth weighing the pros and cons.

About the advantages of own electric car

As for the benefits that will be received by those who decide to change the internal combustion engine to a model with electric traction, here are a few points worth noting:

1. Despite the fact that on the territory of our state there are practically no gas stations equipped with "chargers" - special charging points - it is possible to make up for the energy loss of a vehicle even at home. You can recharge the engine of an electric car from a conventional outlet, which is much more profitable than using electric charging stations, which, due to the fast charging rate, are more likely to make the batteries unusable.
2. Due to the transition of all electrical appliances to night mode, it is very economical to charge the electric motor.
3. No need to carry out complete replacement"stuffing" cars. It is quite simple and bold to use an electric car.
4. You no longer have to get into trouble in the middle of the track due to a sudden breakdown or running out of gasoline. In a hybrid car, you can "reach out" to the place you need, using only the car's reserve traction.
5. Due to the possibility of overcoming short distances on the power of one electric traction, you will get rid of the constant starting of the car and you will no longer have to spend time warming up the engine in the cold season.
6. To prevent damage to the vehicle during rains, simply turn off the electric traction mode.

On the weaknesses of electric vehicles

Do not rush to start converting a car into an electric car without knowing about problem areas such transport:

1. To begin with, take into account the fact that you will not be able to completely transfer the car to electricity consumption. Although even a partial rejection of combustible fuel will save you a significant amount.
2. By artificially changing and increasing the number of parts in the vehicle, you will shorten the time. But given the fact that with the adequate use of a four-wheeled companion, it is quite realistic to make sure that the constituent elements necessary for an electric car are eternal.
3. By increasing the devices of the car, its weight will increase slightly, which may affect its dynamics.
4. Additional details will reduce the free space of the luggage compartment and the cabin itself. Therefore, if you have a large family, be prepared for the fact that the creation of an electric car will entail this kind of inconvenience.
5. In the event of a rear crash, there is a significant risk of knowing exactly how the batteries will behave. Despite the fact that explosions are impossible in theory, do not rule out the possibility of developing a scenario that could lead to a disastrous outcome.

Let's start the refurbishment

If you are really interested in how to convert a car into an electric car, then we suggest you use the working algorithm:

1. First you need to choose a car that will be subject to conversion.
2. The second step is to choose an electric motor that you will have to integrate into your machine. It is best if this is a model that does not require the involvement of specialists for maintenance. DC motors with a small body are perfect. Search on secondary market motors from electric cars, clean them of old grease and take care of cleaning the terminals.
3. After that you need to buy rechargeable batteries for the future electric vehicle.
4. Now we can shoot old motor and remove the battery.
5. Install an electric motor in place of the dismantled internal combustion engine, and batteries in place of the battery.
6. On the roof of the car, place a solar panel that will recharge the batteries. You can easily afford it, which will provide your four-wheeled friend with the energy to turn on the turn signals and headlights. However, over time, take care to install an additional battery.
7. Connect the ignition switch directly to the contactor.

Selecting a vehicle to be modified

To create an electric car, it is best to choose vehicle that meets the following criteria:

1. It is a fairly common model in your area. This will make it easier for you to find spare parts. Give preference to cars that are light in weight to provide them with a long and fast ride. The ideal would be the choice of a two-seater passenger car, not exceeding a ton in weight.
2. For an electric car to be fast, it is important to have a rounded body with good aerodynamics. Otherwise, gusts of headwind can "steal" from your top speed up to 15 kilometers per hour.
3. Between mechanical box gears and automatic, give preference to the first.
4. Be sure to find out if the model you like has enough space for batteries. It is important that you have enough space to service the batteries. Please note that it is necessary to mount the batteries as low as possible, evenly distributing the weight throughout the vehicle. This will directly affect the handling of your electric vehicle.

If you have difficulties at the stage of buying batteries, because you lack knowledge in this matter, then use our tips:

1. Before starting the formation of an electric car, take care of purchasing 2 batteries - the main one and a spare one. Performs very well in use gel battery. Being one of the subspecies of the lead VRLA battery, it does not require constant topping up of water.
2. A lithium-ion battery will cost you a little more. By choosing such a model, you can decide what voltage and maximum current you need.
3. Please note that for the normal operation of an electric car with passengers, it is necessary that the battery produces a voltage of at least 75 volts, and its capacity is at least 40 ampere-hours.

We replace the old motor and battery

Before joining the community of electric car owners, you have to take care of dismantling the old motor and battery. For this you need:

1. Using a hoist and a torque wrench, pull the old motor out from under the hood.
2. Remove all the parts that made the internal combustion engine work, and leave only those that will be necessary for the life of the electric vehicle.
3. If available, cut off the hoses that are connected to it from the body and close with tubes and clamps. The electric vehicle must be on conventional steering.

After eliminating unnecessary elements, you can proceed with the installation of the components of the electric vehicle. First of all, you have to make special mounts for the electric motor in order to connect the latter to the gearbox. To do this, measure the space of the existing holes and those that will be required in the future. To replace the engine correctly, do not neglect the following points:

1. Instead of making new mounts, it is better and easier to simply modify the existing one, since they are already provided with cushions that absorb the vibration of the motor. Just attach new engine to the old mounts and drive the car to the service, where they will carry out the residual work.
2. To connect the gearbox to the motor, use a new flange and adapter. Alternatively, you can connect the engine shaft to the transmission by using a redesigned flywheel.
3. Then carefully install a new electric motor and power controller in the engine compartment.
4. Use the brackets to secure the batteries, and use a wire with an M50 or M70 section to connect the battery pack to the controller. How the lithium-ion or gel batteries will be located is entirely up to you. In the matter of installation, be guided by how convenient it will be for you to maintain these parts.

Taking into account all of the above, we would like to give you one more valuable and very practical advice: trust the professionals in the selection of components for converting your car into an electric car, if possible. Today, ready-made kits are slowly appearing on sale, which are designed for certain car models. If there is no such kit for your four-wheeled comrade, you can always arm yourself with welding or find an inexpensive, but very good workshop that will help you become the owner of an economical electric car.

By having an electric car, you will save money on fuel in the first place, which is great for the environment. We hasten to please you that you can build an electric car with your own hands even using the most ordinary car.
We offer you a series of instructions that you need to follow in order to create an electric car with your own hands.

Step 1: Choose a car from which you will make an electric car with your own hands

It is best to choose a common brand, this will make it easier for you to access numerous spare parts (and you will definitely need them). The simplicity of the design of applicants when choosing, in this case, is welcome (the simpler the better). Another important detail is the weight of the future electric car, which you will create with your own hands. It must be remembered that our future car will gain a lot of weight thanks to the battery. by the most the best option to build an electric car with your own hands, convertibles or cars up to 2 tons are considered.
If you want your future electric car to pick up speed well, look for a well-streamlined, aerodynamically shaped car for minimal drag (alternatively, additional optics can be created later with your own hands separately). Excessive wind resistance will typically take 10 to 20 km or 8.0 to 16.1 km/h off your electric vehicle.
For electric vehicles in general, there is no need for a gearbox, as the ability to drive forward and reverse is handled by the controller.
The electric car that you are going to build with your own hands must also have enough space for electric batteries to provide enough voltage to power the engine. It is also worth remembering that when creating it, you need to take into account the possibility of having constant access to the batteries for easy do-it-yourself maintenance. Don't forget also that the uniform placement of batteries in the vehicle space is directly responsible for the stability of your electric vehicle.

Video: How to make an electric car with your own hands

Step 2: Choose an engine for your electric car that you can build as you like by installing it yourself

Find what you need, does not require a professional level of knowledge. The DC motor is the standard motor for building almost all electric vehicles. It will even be enough to find such a motor in a used condition and restore it. This task is quite simple (what you need to do with your own hands is to disassemble the case, clean and degrease the electric motor, and then restore all its connectors).

Step 3: Buying an Electric Vehicle Battery

Before you start assembling an electric vehicle, you will need a main battery and a backup battery. You need to look for a helium cell battery, which is a type of regulated lead acid batteries containing a thickened electrolyte. Such sealed (without revision) batteries do not require additional do-it-yourself pouring of distilled water into the battery cells of the future electric vehicle. This is a sealed accumulator with a pressure relief safety valve. When buying, you can explain to the seller for what purpose you need the battery.
A more expensive option is to purchase lithium-ion batteries. I must say that they are quite expensive, have a variety of voltages, but this option allows you to purchase almost one battery instead of completing a number of smaller ones. After all, in order to pull such a battery big car with passengers and drive a decent distance - you will need a total of 72 volts and 40 to 60 ampere hours. If you want the car to develop up to 64 km / h, then it is better to take 144 volts and about 80 ampere hours. Although, many car builders who want to create an electric car with their own hands purchase lithium-ion batteries.

Step 4: Remove the old engine with your own hands

You will need a beam crane and a set of keys to help you remove the engine and old parts from the car. If the old and rusted bolts are poorly unscrewed, use a liquid key (it is available in all car dealerships).
We take out the engine and everything else that we do not need to work in conjunction with the electric motor: a tank, exhaust system, radiator, etc.
Whether or not there was a power steering in your future electric car that you create do it yourself not so important, since you can always install electric power steering as an additional option.

Step 5: Install the motor and battery in place of the old unit

This is where the gearbox mounts can be reused. We connect the electric motor to the gearbox and support it with a jack, measure the difference between the old engine mounting bolts and electric motor and install it.
You can make and mount a brand new engine mount, but it's much easier to use the original engine mount as it has dampers built into it to avoid dynamic engine stress. This reduces vibration and rattling when the engine accelerates or decelerates.
You will also need an adapter plate to connect our electric motor transmission and clutch (specially designed to mate the engine flywheel and cardan shaft to the transmission).
It's best to bring the motor and gearbox to a workshop and use a simple piece of cardboard to measure the distance between the bolt holes on one side and the electric motor bolt holes on the other.

Position the motor inside the front of the vehicle and connect the controller. The controller, as a rule, can be 72 volts (like the controller on any golf car, for example). However, if you want a 144 volt controller, you will need to find sites that sell them specifically for electric vehicles.
Install the battery (using the battery fasteners). Connect the motor and battery to the controller.

Step 6: Installing the solar panels of an electric car with your own hands

The installation of solar panels will be used as passive energy for battery backup. They choose very different places. Naturally, it is worth placing them in places on an electric car with good access to sunlight (it occurs when craftsmen creating an electric car with their own hands place them even on the turn signal mirrors). Why not?

Step 7: Connect the ignition to the starter

The starter activates the motor when the key is turned. This will operate in the same manner as a powered ignition switch. You will need to solder the ignition so that it turns on the starter of the electric car. To do this, connect the wires to the car's electrical system and the fuse box. You will also need a pedometer that connects to throttle and gas pedal cable. This wire is connected to the controller and gives it a signal when it is time to start moving the electric car. This is a fairly important detail that you may need when creating an electric car with your own hands. .

Step 8: Just buy a kit to convert a simple car into an electric car

Don't buy all the parts separately. You can purchase a kit for converting an ordinary car into an electric car with your own hands. It will have all the necessary components and they will be 100% designed to work together. However, such kits, as a rule, are not universal for all cars. You will still need to make a lot of items in case the kit doesn't fit your car.