Seating In Carbon Brushes Day 1-5

I am seating in H60 carbon brushes for more than five days now.

Running day and night a WarP 9 at 12V.

They are more or less half done after 125 hours.

After 125 hours runtime.

After 93 hours runtime.

After 73 hours runtime.

After 18 hours runtime.

May The 4th Be With You

Charge Force

 Two more Brusa chargers.

The tower of power.

The software setup takes only one minute.

Shooting Day

We were in Frankfurt am Main.

Shooting the second time a commercial for a german bank.

2.0 Updated to a better link.

Cruise Control

New WarP 9 and 11 motors will be available soon.

EV Grid

My 220VDC/AC 3KVA singel phase inverter arrived today.

First surprise, it is 15kg / 33 lbs lighter than described.

Second surprise, it can switch without interference between AC and DC input back and forth(Bypass transfer time ≤4ms).

That allows me to prepare the film light without draining the battery pack.

eDashboard Design 1.1

I have a JLD404 to show the pack voltage, amps and Ah.

I also have a JLD404 to show my motor voltage, amps and watts. Thats new.

The 5740 is showing one battery and will stay until I have another meter to monitor my 13 volt system.

Now two JLD7100 to show the liquid cooling and battery temperature.

And a second JLD404 to show and monitor my Inverter voltage, amps and watts.

I want to have a EU standard 220 volt / 2400 watt AC system, to run a 1,8 kw HMI lamp and some film stuff.

The inverter is ordered and will hopefully arrive in april.

Freezing For Science

With an outside temperature of 2-3°C(about 36°F), I repeated my test drive of 202km and WestWind.

I have not expected to freeze in the car like that....but everything was going good (aside from my legs. It took two hours to thaw them again.)

 First I was driving 100Km (62miles) mostly freeway at 100Km/h (62miles/h).

I used 1,03 Ah/Km from my 70 Calb 180Ah pack. Thats in increase at about 30% because of the low temperature.

On the second part of the test drive I was driving 90Km (56miles) country road. I decrease the max. speed at 80 Km/h (50miles/h). A lot of 70 Km/h (44miles/h). So I came back to my energy consumption and the range I was used to.

This was only for test reasons. An electric car should drive at normal speed at any weather.

It would be nice to test a heated and isolated pack in winter.

Then we could see the power consumption of the battery pack heating against the performance increase of the battery pack.

eLandcruiser

Right now I'm a little bit more busy on my Land Cruiser blog.

EV-REBBLlion

I was visiting REBBL in the Netherlands today.

They convert young and oldtimer to electric and are the European dealers for Evnetics selling the Soliton controler with EMC.

Nice people with good experience.

WarP 11 ™ Motor In Stock

Just arrived in Hamburg, Germany

WarP 11 Series DC Motor

Double ended shaft - advanced timing, 1.125" DE Keyed Shaft* CE Keyed Shaft*, lift-eye bolt hole, thermal switch ( opens at 150 degrees C) Inkl. a Keyway and a Lift Eye Hook

Optional with Hellwig H60 RedTop Split brush kit.

As an authorized international Netgain dealer this WarP 11 is for sale.

Inquiries at: netgain@ccp-film.de

Work And Travel

First Full Electric Camera Car

WarP 9 ™ Motor In Stock

Just arrived in Hamburg, Germany

As an authorized international Netgain dealer this WarP 9 is for sale.

Inquiries at: netgain@ccp-film.de

Top Speed

I wanted to make a whole new EVDrive film. But there is something wrong with the microphone...it is much to silent. So only this little clip.

The Soliton1 has liquid cooling now with a water pump that is running the whole time. This gives me a stable water temperature at about 28°C at 12°C outside temperature. The fan will be switched by the Soliton1-output -water pump via  a relay. But I don't think the fan will run in the next seven mounth.

Pipe Thread

Some days are worse than others...

DC-DC Converter

 My first self-made DC-DC 5V board..

..to run my Wi-Fi router.

Input filter with an inductor and a capacitor.

EV cooling System

The  shop is working again.

I did a test drive at 22°C (72°F) outside temperature with the now closed hood.

On the Autobahn the Soliton1 reached the 65°C (150°F). While the controller alarm started to blink he changed from 14 KHz to 8KHz and derated the motor current.

Liquid cooling is not an option. It's a must.

 In search for the best working and best looking place under the hood.

 This will work and can be welded together..

Bad Boy Charger

I am thinking about a fast charger...

Last night I have been reading a bit into the topic.

We have 230V singel phase and 380-400V three phase 16/32/63A 50Hz here in Germany. As I unterstand it, a 3 phase Rectifier will give me 1,414(TRMS) times the voltage in DC. That will give me 540-565VDC. To smooth out the DC current I need an inductor and a capacitor.

I need 246VDC max.54A to charge my 70 SE 180 AHA CALB's. I don't know if I can do this by an three phase AC transformer or with an IGBT on the DC side? It should be simple and low-priced.

If I have to spend money, then better in a few more cells.) But not another 84 cells.

Also I think about an inrush current limiting not always to blow the house fuse....

Company Move

Nothing is going on because company move.

Bye you good old hut.)

Welcome new base

Elektra Is Dressing Up

The color is original Citroen 2CV. AC118 Gris Etna

Gearbox Output Shaft

The gearbox output shaft was not running in center. The ball bearing shaft sitting was too small. The shaft had to be built-up by chrome plating. It took four weeks...

...but finally the shaft its running perfect.

Elektra holds her breath for a while. Pneumonia.(

EVDrive 16/2012 Time Delay

The Franzbox

The Franzbox arrived today.

EV "Save Your Components" Bodywork

I do not need a radiator grill hole, because through the hole rain water and dust is coming directly to and in the electric motor. That will shorten the lifetime of our brushes and commutator a lot.

Edge Setter & Hole Punch Plier

Switch Box Brainstorming

For the next step I would like to use an electronic timer relay but one that switches the precharge circuit also "off" after the main circuit is "on".

Perhaps I have to use two of them.
One with a switch-off delay for the precharge circuit for 20 sec. runtime and the second with a switch-on delay of 10 sec...

Battery pack switch box for the charger

This battery pack switch box with a precharge resistor is a test version. I have two switches. One is for precharging and the second is for direct contact. It is two switches in parallel.

I use a 25 watt high power wirewound resistor with 1 kΩ

direct battery: off   precharge: off

direct battery: off   precharge: on

direct battery: on   precharge: off

Circuit

The 51 Cell Battery Box

29,4 kWh

EVDrive 15/2012 West Wind

The 19 Cell Battery Box

11kWh

Welding Work

The gearbox and motor mount was fixed by strong welding points. Now I can finish the welding.

Gear Shift Redesign

I decided to mount the charger in the front. So I need every cm in inch to make it fit. Some sand in the gear shift tube and some fire and it fits perfect.