OSEV CONFIGURATIONS
Updated 10/20/08
The following configurations are being considered so far:
| Project: | 1. State-of-the-art | 2. Economy | |||
| Item | Goal | Configuration #1a | Configuration #1b | Configuration #1c | Configuration #2 |
| Donor car | 2005 Ford Focus ZXW SE wagon | same | same | 1980 Plymouth Horizon | |
| Initial Curb weight | 2768 lb | same | same | 2250 lb (est) | |
| Initial Payload | 1032 lb (see note 1) | same | same | 875 lb (est) | |
| ICE weight removal | 405 lb (see note 2) | same | same | 370 lb (see note 2) | |
| Batteries | 13 Valence Technologies Epoch EEV-19-65 250V, 15.8 kWh actual (see note 3), 65 kW peak (see note 4), 29 kW continuous (see note 5), 445 lb, $20,095 direct from manufacturer per quote | 84 Thunder Sky TS-LFP60AHA 268V, 15.0 kWh actual, 160 kW peak, 48 kW continuous, 462 lb, $8,568 from Elite Power Solutions per website | 100 Hipower HP50Ah (see note 6) 320V, 14.9 kWh actual, 32 kW if held to 2C per spec, 460 lb, $7,500 from Make Mine Electric at "cost plus" special discount per quote | 32 Hipower HP100Ah 102V, 9.5 kWh actual, 20 kW peak and continuous if held to 2C per spec, 294 lb, $4,800 from Make Mine Electric at "cost plus" special discount per quote | |
| Battery Management System | Integrated in modules, plus Valence EBMU, $130 | Thunder Sky $30/cell estimate; $2,520 total | TBD $30/cell estimate; $3,000 total | TBD $30/cell estimate; $960 total | |
| Drive System | Azure Dynamics AC24LS motor and DMOC445 controller estimated 43 kW peak/18.0 kW continuous output at 250V in wye configuration (see note 7), 121 lb, $6,090 from Electro Automotive | same; estimated 44 kW peak / 18.5 kW continuous | same; estimated 17 kW peak / continuous if batteries kept to 2C per spec; 45 kW peak if batteries allowed to 5C | Navitas SRE600-96 Series DC motor controller and 96V 8" Advanced DC motor (using used Prestolite motor); estimated 15 kW peak / continuous if kept to 2C; 45 kW if batteries allowed to 5C; 120 lb, $2,450 from Thunderstruck Motors | |
| On-Board Charger | 2 Brusa NLG513-SCs in parallel 6.7 kW at 240 VAC, 1.6 kW at 120VAC, 27 lb, $7,416 from Metric Mind including cables | same | same | Zivan NG1, 5 lb, $550 from Thunderstruck Motors | |
| Console | Custom | same | same | same | |
| Miscellaneous other EV items (see note 8) | 125 lb (75 front 50 rear), $3,300 | same | same | same | |
| Final weight | 2973 lb | same | same | 2424 lb | |
| Estimated average DC energy consumption rate (see note 9) | 262 Wh/mi | same | same | same | |
| Final payload | >700 lb | 719 lb | 702 lb | 704 lb | 701 lb |
| Total EV component cost for one set, including 8% tax except Valence (TX) but not shipping | <$15K at volume for State-of-the-art $7.5K for economy | $38,375 (requires 61% volume discount to meet goal) | $30,125 (50%) | $29,490 (49%) | $13,024 (73%) |
| Estimated range at 80% capacity | >50 miles State-of-the-art 25 miles Economy | 48 miles | 45 miles | 45 miles | 29 miles |
| Estimated 0-60 MPH time (see note 10) | <15 seconds State-of-the-art <30 seconds Economy | 18 seconds | 17 seconds | 17 seconds if batteries allowed to 5C (42 seconds if 2C) | 51 seconds |
| Estimated top speed (see note 11) | >80 MPH | 79 MPH | 81 MPH | 81 MPH if batteries allowed to 5C (51 MPH if 2C) | 81 MPH if batteries allowed to 5C (51 MPH if 2C) |
| Estimated maximum flat continuous speed (see note 12) | >70 MPH | 69 MPH | 70 MPH | 71 MPH if batteries allowed to 5C (44 MPH if 2C) | 71 MPH if batteries allowed to 5C (44 MPH if 2C) |
| Estimated max continuous speed up 6% grade (see note 13) | >45 MPH | 42 MPH | 43 MPH | 44 MPH | 44 MPH |
| Minimum full charge time | <3 hours State of the art, <12 hours economy | 3 hours (charger limited) | same | same | 12 hours |
Notes:
1. 1032 lb payload assumed if 3800 GVWR on door - 2768 curb per kbb.com, assuming wet, but it says 827 lb on the door...
2. 405 lb Focus wagon ICE weight removal (312 front, 93 rear):
250 lb 2.0L engine (front)
78 lb 13 gallons of gas (rear)
35 lb starter battery (front)
20 lb exhaust system (1/2 front and rear)
17 lb full radiator(front)
5 lb gas tank(rear)
The 1.7l VW motor used in the Horizon is estimated at 215 lb, for a total of 370 lb (277 front, 93 rear).
3. Actual kWh extracted from batteries = nominal cell voltage x # of cells x Ah capacity of cells x 93% based in measured results, due to high current I2R losses.
4. Peak battery power estimated by (nominal voltage - voltage drop across 2 milliohms per cell at peak current) x peak current
5. Continuous battery power estimated by (nominal voltage - voltage drop across 2 milliohms per cell at continuous current) x continuous current
6. Verify 425V peak during charging is OK for Azure per 450V "on charge" and 400V "max operating" voltage specs.
7. Motor power estimated by interpolating voltage between 156V and 312V and the powers given at two levels, assuming linear, but they are at different configurations (delta vs wye) so this may not be accurate -- see vendor for exact values.
8. Other EV component weights and prices to be detailed here -- cables, DCDC converter, battery racks, heater, aluminum plate, motor adapter, splash shields, etc.
9. 262 Wh/mi for AC Focus based on 340 Wh/mi for Chris' 2971 lb DC LiFePO4 1966 Mustang * .90 AC drive + regenerative braking * .95 front wheel drive * .95 better aerodynamics * .95 LRR tires
262 Wh/mi for DC Horizon based on 340 Wh/mi for Chris' 2971 lb DC LiFePO4 1966 Mustang * .95 front wheel drive * .95 better aerodynamics * .95 LRR tires * .90 weight reduction
10. 0-60 MPH acceleration time estimated by linear estimate of 23 seconds for Chris' 33 kW peak/peak of motor.
11. Top speed estimated by square root difference in power compared to Chris' 70 MPH at 33 kW peak.
12. Continuous flat speed estimated by square root difference in continuous power compared to Chris' 65 MPH at 16 kW.
13. Continuous 6% grade speed estimated by square root difference in power compared to Chris' 40 MPH at 16 kW.