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Electric Fiero

Electric Fiero. David Malloy. Fiero Project Goals. Battery Electric Car for commuting and in-town errands Range: Daily commute is 12 miles (round trip) and flat Speed: Need to keep up with traffic; top speed of 65 mph Payload: 2 passengers with need for minimal trunk and storage space

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Electric Fiero

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  1. Electric Fiero David Malloy

  2. Fiero Project Goals • Battery Electric Car for commuting and in-town errands • Range: Daily commute is 12 miles (round trip) and flat • Speed: Need to keep up with traffic; top speed of 65 mph • Payload: 2 passengers with need for minimal trunk and storage space • Safety, Construction Quality, and Appearance Important • Designed and constructed with reliability and safety in mind • Should not require maintenance but should be easy to maintain • Did not want to push the technology envelope. Wanted: • a high probability of success • to copy examples of successful conversions • a ready source of parts and support • Willing to build a prototype and to compromise (on certain things) if necessary • Wanted to have fun, not to achieve perfection

  3. Fiero Project Timeline

  4. Fiero Decisions • Donor: 1988 Fiero • Many successful conversions (e.g., evalbum.com) • Readily available and cheap parts • “Back to the future” styling • 144V Kit and Design from EV America (www.ev-america.com) • Excellent email support, DVD, Reference schematic • One stop shopping for: motor, controller, controller radiator plate, adapter plate, charger, DC/DC converter, fuse, vacuum pump, contactors, Anderson connectors, Inertia Switch, welding cable,etc. • Machine shop service for adapter plate (Clutchless design) • Major Features • Advanced DC 9” motor / Curtis Controller • 12 * 30XHS Trojan Lead Acid Batteries (with “UT” terminals) • Zivan NG3 220V charger; Zivan NG1 DC/DC Convertor • Suspension upgrades would be required for added weight

  5. Fiero Battery Boxes • “Erector Set” construction: cheap; easy to build and change. Not optimized for space or weight

  6. Motor Adapter • Direct Drive • Single gear (e.g., Tesla) • Clutched • When starting, put into gear and release clutch FIRST, then accelerate • When moving, shifts like a normal manual transmission • Provides additional failsafe under controller “stuck on” failure • Clutchless • When starting, put into gear, then accelerate (like an automatic) • When moving, requires finesse to change gears without a clutch • Removes flywheel and pressure plate • Fiero uses the clutchless design • See Pictures below • from SveinMedhus’ Ford Express conversion. (http://www.geocities.com/CapeCanaveral/Lab/4429)

  7. Clutchless Adapter

  8. Clutchless Adapter (2)

  9. Clutchless Adapter (3)

  10. Clutchless Adapter (4)

  11. Fiero Layout

  12. Fiero Layout Notes • High Voltage / High Current • 2/0 Welding cable, crimped lugs, Noalox, Anderson connectors • Layout designed to keep “+” and “-” physically separate • Conduit and “boxes” in tunnel (fuse, contactor, KSI, shunt) • High Voltage / Low Current • Conduit in tunnel • Contactor Control • in cabin against rear firewall • Instrumentation • Jacketed cable used in cabin to bring high voltage to dash • Weight Distribution • Most batteries are on the “outside” of the axles – not ideal

  13. Fiero Front

  14. Fiero Secondary Contactor Box

  15. Fiero Rear

  16. Fiero Rear (2)

  17. Alternate Layouts • from evalbum.com • “The good, the bad, and the ugly” • Concerns • battery hold-down construction • maintainability and access for battery watering • exposed high voltage • physical proximity of pack “-” and pack “+” • distance of controller to motor • wiring neatness

  18. Alternate Layout (1)

  19. Alternate Layout (2)

  20. Alternate Layout (3)

  21. Alternate Layout (4)

  22. Alternate Layout (5)

  23. Fiero Wiring Diagram

  24. Fiero Wiring Notes • Traction Pack Wiring (High Voltage / High Current) • Dual contactor design, Fuse, SB350 Anderson connectors • High Voltage / Low Current • Zivan NG3 – 220V/20A Onboard Charger • DC/DC convertor, KSI Relay, electric heater • Contactor Control • Simple relay logic • Primary: ignition key in “run”, charger lockout, inertia switch • Secondary: adds high pedal lockout, potboxmicroswitch • Instrumentation • Curtis “state of charge” • (relative) Ammeter • Charger and DC/DC converter status brought to in-dash LEDs • Motor overtemp • PakTrakr (monitors pack voltage and individual batteries)

  25. Fiero Contactor Control; etc

  26. Fiero Instrumentation State of Charge DC/DC Converter Status Pack Charge Status Ammeter OverTemp PakTrakr

  27. Other Notes • Charging • Charges in ~4 hours (2 to 90%, 2 hours float) • 12V Supply to drive Status LEDs and Exhaust fans • Charging is done outside to vent hydrogen • Vacuum Pump • Enabled when key is in “run” • Conventional installation with Vacuum reservior • Noisy (needs muffler) • Could use more reserve • Electric Heater • Ceramic heater in place of original heater core • Wiring in conduit to relay on real firewall • Operated by original controls and fan • Only wired up ½ of the element: doesn’t work well • Extras • “Reddy Kilowatt” badging • Beep on Backup • LED lighting • IPOD mini sound system

  28. Results • Success ! • Daily driver; almost 2000 miles logged since January • 0-30mph; performance just fine; keeps up with traffic. • Reliable; only maintenance is once a month watering • Quiet and no hydrocarbon smells • Cool Looking • Project cost ~12K • Areas for Improvement • Range only about 18-20 miles • Handling is “heavy” • 30-60mph performance not so great • Want a lighter donor, lithium batteries, more attention to weight and weight distribution • “Funny noises”: contactor and vacuum pump

  29. Component Scorecard

  30. Wish List for Next Time • Want • More Range • Better Performance and Handling • Better aesthetics (silent operation, nicer donor car) • Opportunity charging • Better instrumentation (data logging, CAN bus, better BMS) • Working heater • More attention to Weight and Weight Distribution • Lighter Donor • Aluminum Battery Boxes • Lithium Pack • AC motor and regeneration • More attention to durability and maintainability • Sealed components

  31. Classic 2 Seaters

  32. Modern 2 Seaters

  33. Sedans

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