Fixing the DC-DC Converter

Porsche 914 EV Conversion

I cringe at the thought of having to send anything back to Electro Automotive for replacement or repair, so I took a chance and dissected the DC-DC converter to see if I could fix it. Here's the DC-DC converter taken out of its black aluminum case.

DAIHEN to supply wireless EV charging stations with WiTricity technology

Green Car Congress

DAIHEN will now use WiTricity’s DRIVE 11 wireless charging system—capable of delivering up to 11 kW of power at efficiencies of up to 94%—as the reference design for its own line of standards-compliant wireless chargers for battery electric and hybrid electric vehicles. WiTricity's DRIVE 11 reference design will accelerate DAIHEN’s product development and enable it to deliver highly efficient and interoperable wireless charging stations that meet global automotive standards.

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Trending Sources

Silicon Mobility introduces new software library and app for optimizing EV, HEV efficiency, battery range and charging speed

Green Car Congress

It includes advanced functions for inverter, DC/DC converter and AC/DC charger systems control. OLEA LIB comes with building blocks available as reference models and target models for MATLAB Simulink, and tuned for best used of OLEA.

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Overflow crowd at DC plug-in conference

Plugs and Cars

And, when his interviewer referred to plug-in hybrids, he insisted that all-electrics be part of the conversation and the commercial vehicle mix. News of oil by the barrel and gas by the gallon reaching new highs had been dominating TV and print, so it was perhaps not surprising that the Google/Brookings Plug-in Electric Vehicle Conference saw overflow crowds.

Sendyne module precisely measures DC current from 3 mA to 500 A over the automotive temperature range

Green Car Congress

Operating in the automotive temperature range of -40 °C to +125 °C, the module simultaneously measures bi-directional DC current through a 100 micro-Ohm resistive shunt, voltage and temperature at 4 points. Accuracy is defined as the cumulative effect of all possible sources of error, including offset, gain and stability of the built-in precision voltage reference. Sendyne has introduced the SFP100EVB, a turnkey module for precision measurement of current, voltage and temperature.

DC 1

Mercedes unveils electric all-wheel drive Vision Mercedes-Maybach 6 show car; CCS charging up to 350 kW

Green Car Congress

Supporting DC charging based on the CCS standard, the system allows an impressive charging capacity of up to 350 kW. The classic circular instruments are combined with deep displays and act as a reference to the history of Mercedes-Benz.

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Electric Cars: Yes We Will

Revenge of the Electric Car

Dateline: Washington, DC. The buzz is everywhere and completely electric in Washington DC this week. Case in point: we opened the paper on our arrival to see a full 1/4 page photo of this message greeting Obama from the sides of the train tracks on his big journey from Philadelphia to DC: Electric Cars: Yes We Can ! " And here in DC, you can’t stop hearing these phrases: green energy, green transportation, and green jobs to build them.

DC 2

"Spirit of DC" Taking on Las Vegas EVA, Monday Eve, 24 November 2008

Spirit of DC - PHEV3A

SEE below for December 2008 contents from Las Vegas EVA Watts Happening -- space that was reserved for Stan & Marianne, Bill and Amanda, Bill, Lloyd, Daniel, John, Michelle, et Las Vegas EVA'rs al for webblogging plus posting pixs of the "Spirit of DC" shining & showing on the 2nd level of the Texas Station Casino parking garage. After answering questions and handing out informational brochures, Jerry joined with LVEVA members to christen the Spirit of DC with the LVEVA logo.

DC 0

DOE to award up to $137M for SuperTruck II, Vehicle Technology Office programs

Green Car Congress

Develop and demonstrate an off‐board bi‐directional DC charging system for plug‐in electric vehicles and evaluate impact of grid services on PEV batteries. Develop a unified reference guide of design requirements, and provide in‐person training and tours that showcase best practice garage/maintenance facilities for natural gas, propane, and hydrogen vehicles.

GM provides technical details of the Gen 2 Voltec propulsion system used in the 2016 Volt

Green Car Congress

On top it has an angled rectangular housing receiving high voltage direct current (DC) cables connected to the battery pack and containing the inverter. The main components of the TPIM are the power board, DC bus capacitor, EMI filters, control and gate drive boards, sensors and busbar.

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Volkswagen to produce XL1 diesel plug-in hybrid at Osnabrück; 261 mpg US

Green Car Congress

The body electrical system of the XL1 is supplied with the necessary 12 Volts via a DC/DC converter and a small auxiliary battery. This first body production stage is referred to as the “bodyshell frame”. The XL1. Click to enlarge.

Plug 33

ARPA-E to award $30M to increase performance of solid ion conductors for batteries, fuel cells

Green Car Congress

Li-ion cells can provide 90% round-trip DC-DC efficiency at relevant rates); and (2) scalability across a wide range of power levels (i.e.,

PHEVLERs are the Zero CO2 Clean Green Machines of the Future

Green Car Congress

The DC and fast charging infrastructures for BEVs are very expensive to construct [ 13 ] & operate, and are wasteful of electricity inversely to the square of charge time (meaning ½ the charge time 4 times the losses, and ⅓ the charge time 9 times the losses). References. [ by Professor Andrew Alfonso Frank, CTO Efficient Drivetrains Inc. and UC-Davis Emeritus and Bruce R. Thomas. Abstract.

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Volkswagen Group planning to launch 6 or more plug-in hybrids from 2014; the role of the MQB in the Group’s electrification plans

Green Car Congress

He was careful to note that “launch” referred to the global launch dates for global product—i.e., DC/DC converter.

Cross Coupé with TDI plug-in hybrid premieres in Geneva

Green Car Congress

Meanwhile, the 12 Volt electrical system is supplied with power via a DC/DC converter. This is referred to as ‘sailing’. Since the energy for the rear electric drive is by wire and does not flow mechanically, this is referred to as an ‘electric propshaft’.

Plug 12

DENSO partners with and invests in FLOSFIA to develop next-gen gallium oxide power semiconductor devices for electrified vehicles

Green Car Congress

Ga 2 O 3 and demonstrated an 86% reduction in on-state loss compared to a SiC reference SBD. ?-Ga To use electric energy more efficiently, energy losses during the DC to AC conversion by the inverter must be reduced, and so DENSO is conducting R&D on low-loss power semiconductors.

Oak Ridge researcher developing autonomous intelligent engines capable of real-time calibration based on driver behavior

Green Car Congress

Malikopoulos has recently begun a DOE-funded project on developing autonomous intelligent plug-in hybrid electric vehicles (PHEVs); he presented an early update at the recent DOE 2012 Annual Merit Review meetings in Washington, DC.

Fuel 12

New study finds GHG emissions from palm oil production significantly underestimated; palm oil biofuels could be more climate-damaging than oil sands fuels

Green Car Congress

The research team included members from the National University of Singapore; Stichting Deltares, The Netherlands; International Council on Clean Transportation (ICCT), Washington, DC; and the University of Leicester, UK. Products from WCSB Oil Sands Crudes Compared with Reference. When peat swamps are drained for agriculture, the peat begins to decompose, and is an enormous source of carbon emissions.

Fuel 16

Transphorm and ON Semiconductor begin production of co-branded 600V GaN cascode transistors

Green Car Congress

At APEC 2015, ON Semiconductor and power conversion specialist Transphorm, building on their previously announced partnership to bring gallium nitride (GaN) based power solutions to market, introduced the co-branded NTP8G202N (TPH3202PS) and NTP8G206N (TPH3206PS) 600V GaN cascode transistors and a 240 W reference design that utilizes them. (A At this year’s show we’re excited to announce complete GaN-specific reference designs with ON Semiconductor.

Freescale S12 MagniV Mixed-Signal MCUs supporting mid-class vehicle growth in China

Green Car Congress

S12 MagniV MCUs address this challenge by integrating an analog front end and MCU, providing a comprehensive single-chip solution for applications such as anti-pinch window lifts, instrument clusters and brushless DC motors. Freescale and Tongji University in Shanghai developed an anti-pinch window lift reference design, which demonstrates the capabilities of the S12 MagniV portfolio. Freescale’s S12 MagniV block diagram. Click to enlarge.

First drive: US spec Audi A3 Sportback e-tron plug-in hybrid; 83-86 MPGe with 16-17 mile EV range

Green Car Congress

lb), the power electronics in the engine compartment, which include a DC/DC converter for connecting to the 12-volt electrical system, are compact and lightweight.

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DOE seeks to cut cost of Level 2 EV charging equipment in half in 3 years; $12M FOA

Green Car Congress

Given that AC Level 2 (L2) EVSE is expected to account for a large majority of residential and commercial EVSE (until standards for DC fast charging for commercial EVSE are established), this FOA addresses development of smart grid-capable L2 EVSE for residential and non-residential applications. Commercial grade EVSE refers to its materials, construction, performance, and enclosures that are UL-listed and meet NEMA certifications for outdoor use.

NRC report concludes hydraulic fracturing poses low risk for causing earthquakes, but risks are higher for wastewater injection wells; CCS impact undetermined

Green Car Congress

Δσ refers only to the radial stress in the exterior region. Washington, DC: The National Academies Press, 2012. Schematic diagram of a shale gas well following hydraulic fracture treatment, with the relative depths of local water wells shown for scale.

Ideal Power, developer of new indirect power conversion technology, prices IPO

Green Car Congress

It also provides buck/boost voltage conversion, bi-directional power transfer, and multiport applications with any combination of independently-controlled AC and DC power ports. The goal of the partnership is to create standard reference designs using IPC’s patented topology in the 3-Port Hybrid Converter that can readily be adopted by commercial and municipal EV fleets, military installations, and public infrastructure. Ideal Power Inc.,

VW unveils Cross Coupe GTE plug-in hybrid concept SUV at Detroit show; 70 mpge; previewing 7-seater SUV in 2016

Green Car Congress

The 12-volt electrical system is supplied by a DC/DC converter. As the power to drive the rear axle flows electronically, the all-wheel-drive system is referred to as an “electric driveshaft”. Cross Coupe GTE. Click to enlarge.

Startup Siluria Technologies developing novel bio-templated catalysts for economic direct conversion of methane to ethylene; potential for transportation fuels

Green Car Congress

Siluria was one of the highlighted companies at last week’s ARPA-E Energy Innovation Summit in Washington, DC. And it just so happens that for this particular reaction [OCM], conventional methods of making catalysts, which are endearingly referred to in the industry as “cook-and-look” and “shake-and-bake”, have not produced the kind of surface that would run this reaction selectively.

Continental puts first 48V hybrid assist system into production with Renault diesels

Green Car Congress

The electric motor transmits power via a belt drive directly to the crankshaft of the combustion engine—an arrangement referred to as “P0 topology.”

Honda launches 2017 Accord Hybrid; 2nd generation two-motor hybrid powertrain

Green Car Congress

The Accord Hybrid's intelligent Power unit (IPU), located behind the rear seat, packages a DC-DC converter and a 1.3 To help make judging distance easier, three reference lines are shown. Honda has launched the 2017 Accord Hybrid ( earlier post ) at its dealers in the US.

Volkswagen Group talks EV charging standards, electrification strategy

Green Car Congress

One of approximately twenty VW Golf blue e-motion prototypes under test in the United States, with Eaton’s 50kW DC Quick Charger, at Volkswagen’s Electronics Research Laboratory, near San Francisco. The gathering marked the introduction of Eaton’s DC quick charger ( link ), one of which is now installed at ERL. public DC charging of up to 86 kW. DC charging” refers to a charging protocol in which a charging station supplies direct current to a plug-in vehicle’s battery pack.

US Postal Service Awards ZAP EV Conversion Contract for LLV

Green Car Congress

Following completion the converted vehicle will undergo field trials in the Washington, DC metropolitan area later this year. 4399, entitled the American Electric Vehicle Manufacturing Act, has been referred to the Committee on Oversight and Government Reform. The United States Postal Service (USPS) has awarded electric vehicle provider ZAP an engineering contract for the design and development of an electric version of its Long Life Vehicle (LLV).

Volkswagen unveils mid-size SUV plug-in diesel-electric hybrid concept at Detroit Show

Green Car Congress

A DC/DC converter supplies the vehicle’s electrical system with the 12V power it needs. This is referred to as “coasting.” Since the energy for driving the rear wheels is electrical rather than mechanical, this is referred to as “propshaft by wire”.

GM launches Volt field quality assessment and service programs

Green Car Congress

Concurrent with upcoming deliveries of the Chevrolet Volt to dealerships in California, Connecticut (Tri-State Metro Area), Michigan, New Jersey, New York, Texas, and Washington, D.C., The center will maintain extended hours during the rollout, and will have a Volt on hand for reference, if need be. General Motors is rolling out the Volt In-Field Quality Assessment Program, which will run to the end of June, as General Motors concludes its production plant start-up phase.

Berkeley Lab scientists unravel structural ambiguities in Li- and Mn-rich transition metal oxides; importance for high-energy Li-ion cathodes

Green Car Congress

The “phase” of a material refers to the arrangement of the atoms with respect to each other.

XL1 dive and drive: Volkswagen aggressively optimizes for efficiency in its sleek diesel plug-in hybrid

Green Car Congress

XL1 represents the third evolutionary stage of Volkswagen’s 1-liter car strategy, referring to the goal set by Prof. The XL1’s 12-volt electrical system is supplied via a DC/DC converter and a small auxiliary battery. XL1s ready to roll. Click to enlarge.

AC Kinetics to showcase next-generation motor control software at ARPA-E Summit; 10-40% reduction in energy consumption and improved performance

Green Car Congress

will introduce its next-generation motor control technology at the upcoming ARPA-E Energy Innovation Summit in Washington, D.C., Internal AC Kinetics testing used an AC induction motor coupled to a large inertia, following a modified EPA city traffic cycle.

Calif. Energy Commission to award more than $44M for hydrogen refueling and alternative fuel vehicle projects

Green Car Congress

DC fast-charging systems typically provide 60 to 80 miles of range in just 20 minutes of charging. Smart-grid enabled charging refers to a system in which computerized controls manage charging to ensure optimal electric power grid function. In two packages of awards, the California Energy Commission approved more than $44 million to expand the hydrogen fueling infrastructure and increase the number of alter alternative fuel vehicles on the road in the state.

EU investing >€3M in research into ultra-efficient aero engines; ULTIMATE project

Green Car Congress

Europe’s Strategic Research and Innovation Agenda (SRIA 2050) outlines a 75% reduction in aviation CO 2 emissions to year 2050 relative to a year 2000 reference.

First round of parts arrive

Honda S2000 EV Conversion

I'm going with an Advanced DC FB1-4001A. Here is picture of the motor with my hand as a reference for the size. Here is the motor controller again picture with my hand for size reference. I finally got some long awaited parts in this week.

Simon Fraser study finds PEV success not tied to awareness of public chargers; implications for policy makers

Green Car Congress

The researchers also recently presented their study to the National Academy of Sciences’ Transportation Research Board in Washington, DC. The survey questions specified these two relatively popular PEV models rather than refer to “electric vehicles” or “plug-in hybrid vehicles” more generally—we believe that reference to specific models would produce more reliable results.

Reflections on Converting a 914 to an EV

Porsche 914 EV Conversion

I often refer people back to specific pages when they have questions about their own conversions. I'm not entirely sure why, but ElectroAuto shipped #2 gauge cable with the AC kit instead of the standard 2/0 gauge cable that came with the earlier 914 DC kit. It's acceleration at zero RPM was less than half the original ICE engine and half of that (at zero RPM) of the Advanced DC 9" motor in the 914 DC kit. If I had to do things over, I might seriously use the DC kit.