OSEV Requirements

OSEV REQUIREMENTS
Updated 10/19/08

Category Number Description
Key Features 1 Kit that fits most late model compact cars with minor mounting variations.
Documentation 2 Textbook that explains how to fabricate, assemble, test and service cars, including theory of operation.
3 Video that compliments textbook.
4 Owner's manual that compliments the original gasoline manual and fits in glove box.
Safety 5 Fail safe.
6 Redundant control for high risk failures.
7 No high voltage in cab or trunk.
8 Traction pack isolated from frame.
9 Charger output isolated from input.
10 Crumple zones left in tact.
11 Redundant accelerator return springs.
12 High pedal lockout.
13 Proper fuses at sources on all new low current circuits.
14 Main contactor opened when pedal up unless circuit in place to open contactor if current exceeds limit.
15 Remote circuit breaker switch under dash unless circuit in place to open contactor if current exceeds limit.
16 Motor controller cuts back, but does not cut off, when voltage or temperature limits are reached.
17 Charger cuts back, then cuts off, when voltage, temperature or current limits are reached.
18 Body grounded during charging.
19 Thermally stable batteries.
20 Cabin heater for defroster.
21 Non-distracting dashboard.
22 UL compatible.
23 No increase in GVWR.
24 Minimum payload:
- 700 lb for 4 seats
- 550 lb for 3 seats
- 400 lb for 2 seats

25 Fully refurbished stock brake system, with vacuum power assist retained if applicable.
26 Fully refurbished stock steering system, with power assist retained if applicable; electric preferred.
27 Battery contents not to enter cab during impact or rollover.
28 Sealed batteries.
29 suspension, horns and lighting systems inspected and repaired as needed
30 Clearly marked high voltage lines under hood, belly and trunk.
31 Safety shields covering all high voltage.
32 Properly sized front and rear battery fuses.
33 Properly sized cables.
34 Forward and reverse claxons to warn people you are coming.
35 Low complexity HW and SW.
36 Sealed components.
37 No traction battery or accessory battery drain when ignition key is off and charger is unplugged; expected storage time without charging >6 months.
38 Easy to drive without damaging components for non-technical busy user.
39 Use components designed for automotive environment – shock, vibration, temperature, humidity, noisy, reliable and 10+ year design life except for known wear items such as batteries.
40 All components operated below their specified parameters – voltage, current, temperature, power, etc. – such that they are designed to last more than 10 years per Reliability Analysis Center Handbook derating guidelines or equivalent per SAE.
41 Locking mechanisms on all fasteners.
42 Motor controller precharge resistor, fuse and relay to reduce the strain of inrush current in the motor controller ripple filter capacitors if motor controller is being switched on and off regularly and the function is not handled inside the motor controller.
43 Mount contacts protruding from sealed cases sideways or downwards to reduce moisture settling inside the parts.
44 Place reverse biased diodes across relay coils to open contacts faster and lengthen contact life, unless integrated inside package like some automotive relays.
45 Charger power or filler door ignition interlock.
46 Crimp connectors to cable ends; do not solder.
47 Either an automatic battery balancing system that works over the >5 year life of the batteries, or manual balancing prompted by "maintenance required" dashboard light that does not need to be performed more often than annually and the pack capacity loses less than 5% due to imbalance.
48 Battery monitor system cuts off charger before any battery becomes overcharged. If charger cuts off before all batteries are charged, driver is alerted via dashboard indicator.
49 Minimum dashboard indicators:
state of charge "fuel" gage based on amp hours and minimum cell voltage
worst temperature gage -- motor, motor controller or batteries
charge status -- red, yellow and green
drive status -- red, yellow and green
heater status -- yellow
Optional indicators:
battery current
motor current
motor RPM

50 Splash shields around all electric components.
51 Ventilation for all electric components.
52 Power cable crimps filled with conductive antioxidant to inhibit corrosion.
53 Bolt-on battery terminals with lock washers, not clamps.
54 No air conditioning or other power options unless absolutely necessary.
55 Strain relief on all wire connections.
56 Scrape protection on all wires.
Easy to Maintain 57 Readily available, widely used components obtainable in low quantities globally.
58 Troubleshootable in-situ on road and stationary, and with components removed and on bench.
59 Simple fabrication and assembly techniques.
Valuable 60 >=2 year full, 5 year prorated warranty on batteries, >=5 year full warranty on all other EV components.
61 Lower cost for higher performance of existing entry level solutions.
62 FCC compatible.
63 Pedal input smoothly accelerates like gasoline car.
64 Door, window, seat, trim, stock instrumentation amd paint inspected and repaired as needed.
65 <1 milli Gauss magnetic field in cab for those sensitive to electromagnetic fields.
Easy to Co-Develop 66 Mimimize or eliminate need to write assembly code; write in C.
67 Maximize use of off-the shelf hardware and software components and reference designs.
68 Inexpensive controller development environment, including eval board that can be bolted right in for development.
69 Controller developer support network – not just from manufacturer.
70 Industry standard interfaces when applicable.
71 Subset and different component solutions anticipated and able to work by simply removing or omitting HW and reconfiguring SW, not reprogramming firmware.
72 Robust HW and SW source control and access.
73 Documentation, test harness and test plan delivered before or along with any design implementation.
74 All results posted on web, accessible by all.

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Category	Number	Description
Key Features	1	Kit that fits most late model compact cars with minor mounting variations.
Documentation	2	Textbook that explains how to fabricate, assemble, test and service cars, including theory of operation.
	3	Video that compliments textbook.
	4	Owner's manual that compliments the original gasoline manual and fits in glove box.
Safety	5	Fail safe.
	6	Redundant control for high risk failures.
	7	No high voltage in cab or trunk.
	8	Traction pack isolated from frame.
	9	Charger output isolated from input.
	10	Crumple zones left in tact.
	11	Redundant accelerator return springs.
	12	High pedal lockout.
	13	Proper fuses at sources on all new low current circuits.
	14	Main contactor opened when pedal up unless circuit in place to open contactor if current exceeds limit.
	15	Remote circuit breaker switch under dash unless circuit in place to open contactor if current exceeds limit.
	16	Motor controller cuts back, but does not cut off, when voltage or temperature limits are reached.
	17	Charger cuts back, then cuts off, when voltage, temperature or current limits are reached.
	18	Body grounded during charging.
	19	Thermally stable batteries.
	20	Cabin heater for defroster.
	21	Non-distracting dashboard.
	22	UL compatible.
	23	No increase in GVWR.
	24	Minimum payload: - 700 lb for 4 seats - 550 lb for 3 seats - 400 lb for 2 seats
	25	Fully refurbished stock brake system, with vacuum power assist retained if applicable.
	26	Fully refurbished stock steering system, with power assist retained if applicable; electric preferred.
	27	Battery contents not to enter cab during impact or rollover.
	28	Sealed batteries.
	29	suspension, horns and lighting systems inspected and repaired as needed
	30	Clearly marked high voltage lines under hood, belly and trunk.
	31	Safety shields covering all high voltage.
	32	Properly sized front and rear battery fuses.
	33	Properly sized cables.
	34	Forward and reverse claxons to warn people you are coming.
	35	Low complexity HW and SW.
	36	Sealed components.
	37	No traction battery or accessory battery drain when ignition key is off and charger is unplugged; expected storage time without charging >6 months.
	38	Easy to drive without damaging components for non-technical busy user.
	39	Use components designed for automotive environment – shock, vibration, temperature, humidity, noisy, reliable and 10+ year design life except for known wear items such as batteries.
	40	All components operated below their specified parameters – voltage, current, temperature, power, etc. – such that they are designed to last more than 10 years per Reliability Analysis Center Handbook derating guidelines or equivalent per SAE.
	41	Locking mechanisms on all fasteners.
	42	Motor controller precharge resistor, fuse and relay to reduce the strain of inrush current in the motor controller ripple filter capacitors if motor controller is being switched on and off regularly and the function is not handled inside the motor controller.
	43	Mount contacts protruding from sealed cases sideways or downwards to reduce moisture settling inside the parts.
	44	Place reverse biased diodes across relay coils to open contacts faster and lengthen contact life, unless integrated inside package like some automotive relays.
	45	Charger power or filler door ignition interlock.
	46	Crimp connectors to cable ends; do not solder.
	47	Either an automatic battery balancing system that works over the >5 year life of the batteries, or manual balancing prompted by "maintenance required" dashboard light that does not need to be performed more often than annually and the pack capacity loses less than 5% due to imbalance.
	48	Battery monitor system cuts off charger before any battery becomes overcharged. If charger cuts off before all batteries are charged, driver is alerted via dashboard indicator.
	49	Minimum dashboard indicators: state of charge "fuel" gage based on amp hours and minimum cell voltage worst temperature gage -- motor, motor controller or batteries charge status -- red, yellow and green drive status -- red, yellow and green heater status -- yellow Optional indicators: battery current motor current motor RPM
	50	Splash shields around all electric components.
	51	Ventilation for all electric components.
	52	Power cable crimps filled with conductive antioxidant to inhibit corrosion.
	53	Bolt-on battery terminals with lock washers, not clamps.
	54	No air conditioning or other power options unless absolutely necessary.
	55	Strain relief on all wire connections.
	56	Scrape protection on all wires.
Easy to Maintain	57	Readily available, widely used components obtainable in low quantities globally.
	58	Troubleshootable in-situ on road and stationary, and with components removed and on bench.
	59	Simple fabrication and assembly techniques.
Valuable	60	>=2 year full, 5 year prorated warranty on batteries, >=5 year full warranty on all other EV components.
	61	Lower cost for higher performance of existing entry level solutions.
	62	FCC compatible.
	63	Pedal input smoothly accelerates like gasoline car.
	64	Door, window, seat, trim, stock instrumentation amd paint inspected and repaired as needed.
	65	<1 milli Gauss magnetic field in cab for those sensitive to electromagnetic fields.
Easy to Co-Develop	66	Mimimize or eliminate need to write assembly code; write in C.
	67	Maximize use of off-the shelf hardware and software components and reference designs.
	68	Inexpensive controller development environment, including eval board that can be bolted right in for development.
	69	Controller developer support network – not just from manufacturer.
	70	Industry standard interfaces when applicable.
	71	Subset and different component solutions anticipated and able to work by simply removing or omitting HW and reconfiguring SW, not reprogramming firmware.
	72	Robust HW and SW source control and access.
	73	Documentation, test harness and test plan delivered before or along with any design implementation.
	74	All results posted on web, accessible by all.