Open Source Electric Vehicle Program (OSEV)
Updated May 24, 2011
STATE-OF-THE-ART ELECTRIC VEHICLE CONVERSION PROJECT
Documents will be added as they are created. Documents requiring updates are noted as "to be updated". Documents to be created and/or posted are noted as "TBD".
Progress Report
- Interim report for AAA: osev_sota_interim_report.pdf
- Blog
- Task list and schedule
- Budget
Project Summary
Design, build, test and document a 50+ mile range freeway capable compact sedan electric vehicle conversion with at least 700 lb payload, regenerative braking, and robust battery protection by December 2010 utilizing Santa Rosa Junior College students, faculty, staff and NBEAA volunteers.
Key Partners
- American Automobile Association: $25,000 2008 Greenlight Initiative Grant
- Santa Rosa Junior College: $6,000 donor vehicle purchase, instructor time and administrative support
Key Suppliers who have provided generous discounts for products and services
- Make Mine Electric
- EV Components
- EV Source
Grant Application Documents
- 2008 Greenlight Grant Pre-proposal submitted June 30, 2008: SRJC-NBEAA_EV_Conversion_Program.pdf.
- Final proposal submitted September 12, 2008: SRJC-NBEAA_EV_Conversion_Program_FINAL.pdf.
- Adjustment submitted October 13, 2008: SRJC-NBEAA_EV_Conversion_Program_ADJUSTMENT.pdf.
Sections in the above documents include:
Summary
Project Objectives
Background
Need
Process and Methods
Expected Results
Success Metrics
Awareness
Qualifications of the Project Team
Budget
Timeline
Planning Documents
- Requirements
- Donor Car Analysis
- Specifications
- EV Component Analysis (TBD)
- Project Plan
- Weight Analysis
Wiring Diagrams
Chassis:
upper left
upper right
lower left
lower right
Detail A: Fused front battery box
Detail B: Fused mid battery box
Detail C: Fused rear battery box
Detail D: Junction Box:
upper left
upper right
lower left
lower right
Parts list, wiring list and design issues spreadsheet
LV PCA: TBD
Detail E: Console
Console PCA: TBD
Detail F, low Voltage EV chassis Wire looms:
upper left
upper right
lower left
lower right
Detail G: Motor temperature sender -- TBD
Temperature sender PCA -- TBD
Detail H: AC Adapters -- TBD
Fabrication Drawings
Motor to transaxle adapter kit:
- assembly cross sectional view
- motor ring
- adapter plate (outline and flywheel housing bolt dimensions to be added)
- hub
starter hole cover (TBD)
Motor mount adapter, front battery box and power steering pump mount assembly kit: (needs updating)
Motor mount adapter (needs updating)
- 3-D sketch
- top view
- front view
- side view
- BMS controller and wire loom mounts
- material list
Front battery hold down
- 3-D sketch
- top view
- front cross section and material list
- Safety shield (TBD)
- Front assembly material list
Engine bay splash shields
- Front splash shield (TBD)
- Bottom splash shield (TBD)
Mid and rear battery box kits -- 2 required: (needs updating)
- 3-D sketch
- rack
- hold-down
- material list
- Splash and safety shield (TBD)
- spare tire well removal and new trunk floor with rear box and spare tire hold down mounting bolt holes (TBD)
- spare tire hold down mount (TBD)
- location of 4 holes drilled under back seat for mid battery box mount (TBD)
Other components:
- Conduit assembly (TBD)
- Radiator tray assembly: assembly custom part detail welded part detail
- Junction box pop-riveted sheet metal base assembly and lid (TBD)
- Power brake pump, tank and regulator mount (TBD)
- Console pop-riveted sheet metal base assembly and lid (TBD)
- AC inlet mount (TBD)
Azure Dynamics DMOC445 AC Induction Motor Controller User Manuals and Software
- Main User Manual
- Pedal Controlled Application User Manual
- CAN Controlled Application User Manual
- Programming Software: TBD
- Monitoring and Logging Software: TBD
Brusa NLG5 Charger User Manuals and Software
- Main User Manual
- Monitoring Manual
- CANBus commands
- Programming Software Installer
- Logging Software Installer
Other Documents
- Theory of Operation (TBD)
- Conversion procedure (TBD)
- Verification procedure (TBD)
- User's guide (TBD)
- Maintenance, Repair and Troubleshooting guide (TBD)
Related Information
- Electric Vehicle Performance Tests - EV Documentation standards - Open source EV conversion organization based in Finland: eCars-Now!
Contact: Chris Jones at chris_b_jones@prodigy.net if you are interested in more information, or would like to help out with this effort.
