Album:2005:06-10 Electric Vehicle
I haven't finished it yet, but here's some of the design so far.
Required components:
- Motor(s): 2 EV Warrior motors.
- Speed controller: Curtis 1204-015 275A 24-36V Golf Cart controller
- Batteries: 6 of 12V 9Ah batteries (from emergency lights - $7 ea)
- Charger: 8A 24V wheelchair battery charger
- Throttle: homemade
- Chassis: homemade (in progress)
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had a 3 pin Microphone-style connector, so I bought a mike cable, chopped off the connector and attached it to some power wires for the battery harness. I found some rubber hose that the wires barely fit in and used that for protection/insulation. (
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with connectors laid out, showing red side still minus insulation (
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for a test runner (sans speed controller) (
bam! [Video, 2.9M] (
I need 0-5k, so I use a portion of the range on this 25k pot. (
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with "machined" hole. :) (
showing speed controller on side and clear cover. I have two extra batteries, I figure if I run out of power I can connect those two up and limp home. (
to mount the potentiometer in. (
to the potentiometer. (
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to limit the pot from 0-5k. (
some power connectors from sheet metal using a drill, a clamp and lots of solder. (
attached to the speed controller using thumb screws. (
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To run for one hour @ 24V and 480W (20A) I need 20Ah of batteries.
But the quoted Ah is for 10 hours, we probably need 25Ah or 30 or so.
To be safe, I got 27Ah.
Charging in 8 hours takes 2-3A (60W) charger. I have an 8A charger,
and plenty of 24V charge on my bus as well.
I bought a Curtis 1204-015 (275A) controller. The model 015 allows
for double braking current (which doesn't matter to me) and has no HPD.
I didn't pick this specific model, I just found it on ebay.
Anyways, this can handle a few kilowatts of power, so it's more than plenty.
The motors are both from EV Warrior bikes. They were rated at 12V,
but many run them at 24V with no problem:
12V, 2210 rpm, .378HP, no load 2.6A, stall 99.2A, stall torque 691 oz-in
24V, 4480 rpm, 1.55HP, no load 2.6A, stall 198A, stall torque 1400 oz-in Allegedly I can get 3HP out of both of them, though I can't quite reach a combined stall current of almost 400A, but that wouldn't be good for the motor anyways. I'm told it's more like .75HP each at 24V and 2210RPM. We'll see what the truth is. I'm hoping to get around 12-30MPH and an hour of run time before charge. That seems entirely possible considering how massive my setup is compared to little electric scooters with smaller batteries/motors.
12V, 2210 rpm, .378HP, no load 2.6A, stall 99.2A, stall torque 691 oz-in
24V, 4480 rpm, 1.55HP, no load 2.6A, stall 198A, stall torque 1400 oz-in Allegedly I can get 3HP out of both of them, though I can't quite reach a combined stall current of almost 400A, but that wouldn't be good for the motor anyways. I'm told it's more like .75HP each at 24V and 2210RPM. We'll see what the truth is. I'm hoping to get around 12-30MPH and an hour of run time before charge. That seems entirely possible considering how massive my setup is compared to little electric scooters with smaller batteries/motors.
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Created with the tool photo album generator a tool written by D. Madison on Fri Nov 11 21:11:50 2022