Untitled document
I. The theory of building and fabricating in a safe manner in a safe environment
A. Respect for high voltage when working around batteries
B. Eye and ear protection when working with metal fabrication
tools
II. Making the transition from an ICE vehicle to an (electric vehicle) EV
A. Evaluating driving range
B. Alternate municipal and private recharge/refuel sites
C. Evaluating up front cost vs. motivation for making transition
to EV
D. Researching the latest EV breakthroughs
1. Where the innovative work is being done
2. Sources of information
E. Considering environmental impact in the building and the
disassembly of an EV
III. Choosing a vehicle
A. Vehicle weight vs. energy capacity demand
B. Vehicle weight vs. range demand
C. Vehicle weight vs. payload demand
D. Vehicle weight vs. horse power demand
IV. Matching vehicle to EV conversion strategy
A. Acceleration parameters
B. Range parameters
C. Alternating Current (A.C.) drive systems
D. Direct Current (D.C.) drive systems
E. Conversion cost and limitations
F. Choosing a prefab EV kit vs. making your own kit
G. Retailers
V. Building a safe product
A. Gross Vehicle Weight (GVW)
B. Weight distribution /vehicular balance
C. Suspension requirements, limitations, modifications
D. Braking requirements, limitations, modifications
E. Incorporating regenerative braking into braking strategy
F. Maintaining the integrity of factory designed crumple zones
G. Modern safety equipment
VI. Proactive planning and ICE vehicle disassembly strategies
A. Preemptive research
B. Having a well thought out plan before start
C. Having a well thought out budget before start
D. Reading the instructions and performing all measurements
before disassembly
E. Verifying availability of all parts and replacement parts
before start
F. Verifying component integrity
G. Verifying component support and warranty
H. Verifying product history and company history
VII. Choosing a battery
A. Battery evolution, technology, innovation
B. Slow charging vs. high speed pulse charging
C. Battery cost vs. expected life, stability, durability,
watt/hour capacity
D. One hour discharge rate vs. 12 hour discharge rate
E. Battery chemical platforms
F. Battery management systems: care, rebuilding/reincarnation,
and protection
G. Charging from regenerative braking
VIII EV Component placement
A. Battery placement
B. Motor geometry
C. Vehicular balance - 50/50 weight ratio
D. Crumple zones
E. Component cooling
F. Ease of serviceability
G. Weather, moisture, heat sealed
H. Shock proof
I. Proper clearance from road, moving parts, suspension, steering, and passengers
J. Suspension load and modification
IX. Braking
A. Regenerative braking from AC drive systems
B. Lack of regenerative braking from DC drive systems
C. Removal of the compression braking characteristics
D. High demand racing and off road braking update kits
E. Brake Fade
X. Ideal parameters for EV drive system vs. conventional gearing
A. Transmission choice, automatic, manual, single drive
B. Final drive, reworking ring and pinion
C. Relatively flat torque curve of an electric motor
D. Wasted mechanical energy transmitting through flywheel, clutch, and driveline differential
E. Reaching the ideal RPM for an electric motor vs. the stock transmission
F. Keep or disregard the clutch
G. Adaptor plate
XI. EV electrical componentry
A. Modern single piece motor controls
B. DC to DC converter
C. On board chargers
D. Pot box
E. Relay systems
F. Battery cable and resistance
G. Battery Management
H. Auto shut down, shunts, overload protection
I. Heat sinks and electronic overheating protection
J. Electron flow
XII. Electron flow/electricity
A. Magnetic fields being manipulated into mechanical energy
B. Alternating current
C. Direct current
D. Electro-magnetic fields (EMF) and canceling EMF noise
E. Meshing the different voltage parameters of OEM manufacturing with the aftermarket componentry of a kit