Built Your Own Electric Vehicle Manual - PDF DOWNLOAD

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7 3/8 x 9 1/4 T echnical / Build Your Own Electric Vehicle / Leitman / 373-2 / Chapter 3

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Build Your Own Elec tric Vehicle vehicle’s popularity. The starter motor systems employed in all of today’s internal combustion engine vehicles are virtually unchanged from the original early 1920s concept. Battery electric vehicles have also been extremely popular in some limited-range applications. Forklifts have been battery electric vehicles (BEVs) since the early 1900s and electric forklifts are still being produced. BEV golf carts have been available for years. Golf carts have led to the emergence of neighborhood electric vehicles (NEVs) or low-speed vehicles (LSVs), which are speed-limited at 25 mph, but are legal for use on public roads. NEVs were primarily offered by car companies during the end of the CA Zero Emission Vehicle (ZEV) Mandate. As of July 2006, there are between 60,000 and 76,000 low-speed, battery-powered vehicles in use in the U.S., up from about 56,000 in 2004 according to Electric Drive Transportation Association estimates. In fact, at the end of my tenure at the New York Power Authority, I managed the LSV donation programs from Ford and Chrysler (GEM) of over 250 vehicles. I believe several thousand vehicles were donated by the car companies to receive ZEV credits for the amount of electric vehicles placed on road in 2003. By the late 1930s, the electric automobile industry had completely disappeared, with battery-electric traction being limited to niche applications, such as certain industrial vehicles. The 1947 invention of the point-contact transistor marked the beginning of a new era for BEV technology. Within a decade, Henney Coachworks had joined forces with National Union Electric Company, the makers of Exide batteries, to produce the first modern electric car based on transistor technology, the Henney Kilowatt, produced in 36-volt and 72-volt configurations. The 72-volt models had a top speed approaching 96 km/h (60 mph) and could travel nearly an hour on a single charge. Despite the improved practicality of the Henney Kilowatt over previous electric cars, it was too expensive and production was terminated in 1961. Even though the Henney Kilowatt never reached mass production volume, their transistor-based electric technology paved the way for modern EVs.

Timeline of Vehicle History Studying vehicle history is similar to looking at any economic phenomenon. iPods are a good example. The first iPod was a novelty; the one hundredth created a strong desire to own one. By the ten thousandth, you own one; by the one millionth, the novelty has worn off; and after the hundred millionth, they’re considered ubiquitous. The same with vehicles—past events shift the background climate and affect current consumer wants and needs. The innovative Model T of the 1910s was an outdated clunker in the 1920s. The great finned wonders of the 1950s and muscle cars of the 1960s were an anachronism by the 1970s. A vehicle that was once in great demand is now only junkyard material because consumer wants and needs change. Figure 3-1 is rather busy, but studying it gives you clues to the rise and fall of the three types of vehicles in one picture—steam, electric, internal combustion—plus the interrelationship between them during the three stages of vehicle history. Figure 3-1 shows that steam has been passed by as a vehicle power source but electric vehicles, dominant in urban areas at the turn of the century, are again returning to favor as the majority of the world’s industrial nations become “urbanized,” but petroleum-based fuels are becoming more expensive and availability more politically dependent. Nearly


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Other Related Web Sites

27min
pages 334-357

State- and Community-Related Electric Vehicle Sites

1min
page 331

Chargers

1min
page 324

Batteries

1min
page 323

General Electric Drive Information Sites

3min
pages 332-333

Controllers

1min
page 322

Conversion Kits

1min
page 320

Suppliers

1min
pages 318-319

Electric Utilities and Power Associations

1min
page 310

Conversion Specialists

1min
page 314

Emergency Kit

1min
page 299

Driving Your Electric Vehicle

5min
pages 296-297

Paint, Polish, and Sign

1min
page 291

Further Improved Cooling

1min
page 290

Improved Cooling

1min
page 289

Junction Box

3min
page 277

Charger System

3min
pages 278-282

Fabricating Battery Mounts

1min
page 267

Low-Voltage System

1min
pages 274-276

Mounting and Testing Your Electric Motor

1min
page 266

Purchase Other Components

1min
page 259

Conversion Overview

2min
pages 252-253

Checking

1min
page 251

Wiring It All Together

3min
pages 249-250

The Real-World Battery Charger

2min
page 236

Charger Overview

1min
page 230

Terminal Strip

1min
page 244

The Manzita Micro PFC-20

1min
page 237

The Ideal Battery Charger

4min
pages 233-235

Batteries and the RAV4 EV Experience

3min
pages 228-229

Future Batteries: The Big Picture

6min
pages 224-227

Tomorrow’s Best Battery Solution—Today

2min
page 223

Battery Construction

4min
pages 214-215

Five Trojan Battery Solutions

4min
pages 219-222

The Gentle Art of Battery Recharging

2min
page 209

Battery Types

2min
page 213

Today’s Best Battery Solution

2min
page 218

Battery Capacity and Rating

4min
pages 207-208

Electrolytes

1min
page 203

Battery Overview

1min
page 200

DC Motor Controller—The Lesson of the Jones Switch

4min
pages 185-187

Conclusion

1min
page 199

AC Controllers

2min
page 189

An Off-the-Shelf Curtis PWM DC Motor Controller

2min
page 188

Today’s Best Controller Solution Zilla Controller (One of the Best DC Controller for Conversions)

5min
pages 190-192

Controller Overview

2min
page 182

Tomorrow’s Best EV Motor Solution

1min
pages 179-180

The Advance FB1-4001

3min
pages 177-178

Polyphase AC Induction Motors

3min
pages 173-175

Compound DC Motors

2min
page 168

Universal DC Motors

1min
page 170

DC Motors in the Real World

2min
page 162

Horsepower

2min
page 157

Series DC Motors

3min
pages 164-165

Why an Electric Motor?

2min
page 156

Late-Model Used Vehicles (Late 1980s and Onward

2min
page 152

Calculation Overview

5min
pages 143-144

Drivetrains

2min
page 136

Going through the Gears

2min
page 139

Automatic vs. Manual Transmission

1min
page 140

Difference in Motor vs. Engine Specifications

2min
pages 137-138

Weight Affects Speed

1min
page 124

Buy Your EV Chassis

1min
page 150

Torque Required and Available Graph

4min
pages 148-149

Choose the Best Chassis for Your EV

2min
page 118

The Procedure

2min
page 112

Weight and Climbing

1min
page 123

Weight and Acceleration

2min
page 122

Converting Existing Vans

4min
pages 104-108

Your Batteries Make a Difference

1min
page 111

Converting Existing Vehicles

1min
pages 102-103

Buying Ready-to-Run

1min
page 99

Mid-1960s to 1990s

19min
pages 75-82

Near Future Trends For Electric Drive

3min
pages 96-97

Third Wave After 1979: EVs Enter a Black Hole

2min
page 74

The 1990s–2000s

14min
pages 83-89

After 1973: Phoenix Rising, Quickly

8min
pages 70-73

1940 to 1989

10min
pages 65-69

Timeline of Vehicle History

2min
page 55

Myth #3: Electric Vehicles Are Not Convenient

2min
page 39

Electric Motors

1min
page 31

Convert That Car

5min
pages 26-29

Electric Vehicles Save Money

2min
page 35

What Is an Electric Vehicle?

1min
page 30

Electric Utilities Love Electric Vehicles

1min
page 50

Why Do Electric Vehicles Save the Environment?

1min
page 44

Save the Environment and Save Some Money Too

1min
page 45
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