9:12am July 27, 2007 - It's Alive!

Porsche 914 EV Conversion

This morning, I hacked together a serial cable to talk with the ccShell program provided by Azure Dynamics to communicate with the controller. You need to contact Azure Dynamics directly to get the.ccs file that works with ccShell; it's not available on their FTP site.

2007 130

Battery Equalizer Schematics Rev 1.0

Porsche 914 EV Conversion

I'm currently working on a battery equalizer for the 914 EV based on the whitepaper at the following link: [link] The above two schematics show the circuit that I'm experimenting with using 12V batteries. It seems to work fine on my bench.

2007 170

V2G Test Drive

Plug In Partners

Xcel Energy announces six-month test drive of plug-in hybrid electric vehicles DENVER - Six plug-in hybrid electric vehicles ( PHEVs ) will be on the road by the end of 2007 as part of a demonstration test of vehicle-to-grid ( V2G ) technology by Xcel Energy.

2007 130

The Cash Back Hybrid

Plug In Partners

By John Voelcker First Published October 2007 Google , a former CIA director , the Natural Resources Defense Council , a U.S.

2007 130

Ford, VW Ante Up

Plug In Partners

2007 Ford Motor Company has embarked on a bold mission to bring back the Escort name in a revolutionary new Plug-in Hybrid vehicle. M omentum for a Plug in Future continues. First, there is this story from Volkswagon. Apparently, VW is set to unveil an Up!-based

2007 130

The 60,000 Volt Question

Plug In Partners

23, 2007 -- General Motors Corp. I f there is any doubt that GM is serious about PHEVs, here is one more story that indicates that they are indeed very serious. GM Could Reportedly Produce 60,000 Plug-in Hybrids in 2010 Source: GreenBiz.com by Jeff Green at Bloomberg OAKLAND, Calif.,

2007 130

The Plug In Scooter

Plug In Partners

Piaggio launches hybrid scooter 02 Aug 2007 Italian manufacturer Piaggio , the maker of Vespa , has launched an environmentally friendly hybrid scooter by mechanically and electronically linking a traditional combustion engine with an electric motor.

2007 130

Here Come the PHEVs

Plug In Partners

Audi Metroproject Quattro T his has been a big week of announcements from car manufacturers. One is from the new auto start up Fisker. Fisker's high end-plug in CNET News Blog Posted by Michael Kanellos Fisker Automotive. Think of it as a marriage between the Chevy Volt and the Tesla Roadster.

2007 130

Ford and Edison

Plug In Partners

Ford, utility join to promote plug-in vehicles Reuters India Sat Jul 7, 2007 DETROIT (Reuters) - Ford Motor Co and power utility Southern California Edison will announce an unusual alliance on Monday aimed at clearing the way for a new generation of rechargeable electric cars, the companies said.

2007 130

Easy as A123

Plug In Partners

P erhaps the most important milestone in developing Plug in Hybrids is the availability of an affordable, practical, and powerful battery pack. Here is a significant announcement by David Vieau , CEO of A123 Systems.

2007 130

The Volvo Recharge

Plug In Partners

A nother major manufacturer is unveiling their PHEV at a car show. This time, it's Volvo. Here's the story from duemotori.com.

2007 130

Tata Takes On Air

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Air-Car Ready for Mass Production Bob Ewig Popular Mechanics May 31, 2007 The world's first commercial compressed air-powered vehicle is rolling towards the production line.

2007 130

Volt for Real?

Plug In Partners

F or those who think that GM is not serious about its new PHEV , the Volt , here is a piece that makes you think they are: The Volt To Be Lutz's Legacy May 21, 2007 So, I heard General Motors’ Bob Lutz on National Public Radio’s “Wait.

2007 130

DOE Funds PHEVs

Plug In Partners

The submission deadline is Thursday, May 31, 2007. T he Department of Energy is moving forward to develop advanced batteries for PHEV s. Here is the story. DOE to Provide up to $14 Million to Develop Advanced Batteries for Plug-in Hybrid Electric Vehicles WASHINGTON, DC – The U.S.

2007 130

Hair Dryers Installed

Porsche 914 EV Conversion

I took a few hours today to get the small hairdryers installed. In order to have a convenient switch to activate the hairdryers, I hijacked the defroster knob switch. I was lucky enough to have this option on my car.

2007 130

Serial Port and Hood Pin

Porsche 914 EV Conversion

Today was a bit slow. I received some AMP pins in the mail that fit the special connectors on the DMOC445 controller. To make the serial port more robust, I crimped the pins onto the ends of the 16-gauge wires and inserted them into the 8-position connector that came with the DMOC.

2007 130

Stamp of Approval

Plug In Partners

E PRI and the National Resource Defense Council have recently released a new study which shows the environmental as well as the economic benefits of plug-ins. Plug-in hybrids seen as vehicles for change A study projects lower emissions and sufficient power grid capacity.

2007 130

Hybrid X

Plug In Partners

T oyota created some excitement with their new Hybrid X vehicle that they unveiled at the car show in Geneva last week. It just might have plug in implications. Here is part of their press release on the new concept car.

2007 130

Dedicated Charging Outlet and Hairdryer Coupling

Porsche 914 EV Conversion

After sleeping for 14 hours last night, I think I'm somewhat recovered from that nasty cold. I dropped by Parkrose hardware after work and picked up some stuff to install in the EV.

2007 130

Initial Fuel Gauge Driver Schematic

Porsche 914 EV Conversion

Since I'm stuck indoors today to recover from a sore throat, I put together the following schematic to drive the fuel gauge based on the pack voltage. Click to enlarge the image) With the exception of the 4N25 opto-isolator, which I salvaged from a dead UPS, all parts are available at Radio Shack.

2007 130

Finishing the Rain Gutter for the Engine Compartment

Porsche 914 EV Conversion

The major project of the day was finishing the rain gutter under the engine compartment lid. The original gutter was too deep and interfered with the rear battery box. As described in a previous post, I purchased a piece of ABS plastic from TAP plastics and bent the edges to make a rain catch.

2007 130

Finishing the Serial Cable and Testing the Fuel Gauge

Porsche 914 EV Conversion

I had a bit more time today to work on some other small projects. Here's the 914 patiently waiting for its rebuilt transmission from Rennsport Systems. It'll be awhile since Rennsport won't start on the rebuild until November.

2007 130

Getting the Tachometer and Lights Working

Porsche 914 EV Conversion

After receiving an updated.css file (ccShell config file) from Azure Dynamics for the DMOC445, I was able to access the EE1SpeedoDiv variable. After setting this to a non-zero value, I attached a scope to pin 25 of the main DMOC connector and (yay!)

2007 130

Replacing the Pilot Bearing

Porsche 914 EV Conversion

I purchased a new pilot bearing for the flywheel to see if replacing it would help with the rattles. Flywheel - it's what's for dinner!

2007 130

Trying a Different Transmission

Porsche 914 EV Conversion

Last week Craig at Camp914 offered to lend me another transmission to see if I had vibrational issues. I drove out to Camp914 this morning. I wish to express much gratitude to Craig for letting me borrow this spare tranny.

2007 130

Hub is back but EE1SpeedoDiv is not there

Porsche 914 EV Conversion

Today had some ups and downs. I got the adapter hub from Electro Automotive back today. I installed it on the motor shaft and, to my delight, it had less than 1 mil of runout and wobble! That's how the hub is supposed to work.

2007 130

Subaru to Begin EV Sales in Japan in 2009

Plugs and Cars

Fuji Heavy Industries (FHI) has issued a press release, according to Green Car Congress , announcing that 2009 rather than 2010 will see the sales of the first 100 electric Subarus in Japan.

2007 130

The Wall Street Journals

Plug In Partners

Fialka Wall Street Journal March 26, 2007 AUSTIN, Texas -- Of all the plans cooked up by cities to combat pollution and global warming, the one hatched here is among the most ambitious -- and, some say, one of the more quixotic. A few months back, a reporter from the WSJ came to our offices.

2007 130

Electric Smart Car ForTwo Delivered by Mercedes

Plugs and Cars

Mercedes-Benz has delivered the first of 100 electric Smart ForTwos to fleet customers in the UK. Coventry City Council will be using the electric Smart in its fleet. Smart Car of America has the most complete report, straight from Daimler, with most of the relevant stats.

2007 130

Popular Mechanics Takes Aptera for a Drive

Plugs and Cars

This wingless Jetsonian vehicle has seemed to me to be too much design, too much gadgetry, too much website, and not enough practical, buildable car. I thought I could smell the vapor. Well, Popular Mechanics asked and the Aptera folks let them in.

2007 130

Recharge IT

Plug In Partners

G oogle proved it is serious about Plug Ins with its new Recharge IT initiative. Here is part of the story. Google.org to to Accelerate Plug-In Hybrid and Vehicle-to-Grid Technology Google.org , the philanthropic arm of Google Inc.

2007 130

Getting the Heater Relay and Sending Back the Hub

Porsche 914 EV Conversion

After putting the adapter hub from Electro Auto onto the motor shaft no less than twenty times, I'm pooped. I tried filing down several different faces of the hub to get the runout and wobble down and failed. It's going back to EA tomorrow morning for a new one.

2007 130

Electric Car Salute to Al Gore in Oslo

Plugs and Cars

Electric cars, including many Th!nk nk City cars and at least one RAV4 EV, turned out in large numbers to salute Al Gore, lining Oslo streets as he drove (in a gasser) to receive the Nobel Peace Prize.

Keeping the Rain Out

Porsche 914 EV Conversion

Since I live in the Pacific Northwest, I get rather concerned that rain entering the engine compartment will cause problems with the electrical wiring. Many other 914 EV'ers have protected their wiring inside conduit boxes and other shields.

2007 130

Those (Not So) Good Vibrations

Porsche 914 EV Conversion

Well, it's time to bite the bullet again and see what I can do about the car vibrations. My friend graciously helped me remove the motor/tranny from the car again this morning and assisted with crude vibration measurements.

2007 130

Excel PHEV Study

Plug In Partners

With Smart Grid, Plug-In Hybrid Cars Could Have System Benefits Physorg Feb 28, 2007 Xcel Energy announced the results of a six-month study related to plug-in hybrid electric vehicles (PHEVs) and how an increase in their popularity may affect Colorado.

2007 130

DCDC Transistor Hack

Porsche 914 EV Conversion

After talking with various people and realizing that the over-current circuitry was making the FET gate pulses way too large, I decided to hack the DC-DC converter circuit. Here's the new circuit (click to enlarge).

2007 130

Debugging the DC-DC waveforms

Porsche 914 EV Conversion

I spent most of Friday trying to figure out just what was blowing the DC-DC converter. Here's my full testbench setup. On the upper left, I have a 156V DC power supply. On the lower-left sits a 12V battery to act as an accessory battery. The 30Mhz $400 oscilloscope sits ready.

2007 130

I Blew it Again! Learning About Soft-Start.

Porsche 914 EV Conversion

After studying the oscilloscope waveforms, I believed that the current sense circuit was way too spikey. This is the "amp adjust" potentiometer output in the C400 schematic.

2007 130

Initial CCPower Schematic

Porsche 914 EV Conversion

In my efforts to debug the failures of the DC-DC converter, I tried to capture a schematic of the board. I didn't have time to create a component for the SG3525A controller, but all the pin numbers are listed.

2007 130

GM Volts Ahead

Plug In Partners

Here is part of the story from the Flint Journal Detroit shocker: GM unveils plug-in hybrid - and plans to build it The Flint Journal Sunday, January 07, 2007 By Todd Seibttseibt DETROIT - General Motors unveils a shocking concept car today: the Chevrolet VOLT.

2007 130

A123 & LG Chem Battery Packs for Chevy Volt Unveiled at EVS23

Plugs and Cars

GM-Volt.com is reporting on battery announcements at EVS23. Both A123 and LG Chem/Compact Power have delivered packs to GM for testing in the Volt.

2007 130

Entourage Star Breaks Parking Law in BMW Hydrogen 7

Plugs and Cars

It's a shame the video on TMZ.com doesn't include the reporter's voiceover, because the narration I heard when the story aired on TV caught the reality of hydrogen hype better than most serious enviro journalism. Automakers using movie stars to greenwash was its essence.

2007 130