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Build Your Own Electric Vehicle, Third Edition, 3rd Edition

by Seth Leitman, Bob Brant

February 2013

Beginner

352 pages

13h 14m

English

McGraw-Hill Education TAB

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Cover
About the Authors
Title Page
Copyright Page
Contents
Preface
Acknowledgments
1 Why Electric Vehicles Are for Today!
Build That Car!What Is an Electric Vehicle?Electric MotorsBatteriesControllersHave You Driven an EV Lately?Electric Vehicles Offer a “Total Experience”Electric Vehicles Are Fun to DriveElectric Vehicles Make a Difference by Standing OutElectric Vehicles Save MoneyElectric Vehicles Are CustomizableSafety FirstElectric Vehicles Save the EnvironmentElectric Vehicle Myths (Dispelling the Rumors)Myth #1: Electric Vehicles Can’t Go Fast EnoughMyth #2: Electric Vehicles Have Limited RangeMyth #3: Electric Vehicles Are Not ConvenientMyth #4: Electric Vehicles Are ExpensiveThe Disadvantages of Electric Cars Have Been Reduced or EliminatedTime to Purchase/Build Your Own Brand-New Electric Car!Get Your EV Built!
2 Electric Vehicles Save the Environment and Energy
Why Do Electric Vehicles Save the Environment?Save the Environment and Save Some Money Too!Petroleum Will Not Last ForeverClean Energy Is the FutureFuel-Efficient VehiclesTime Is Running Out!U.S. Transportation Depends on OilIncreasing Long-Term Oil CostsWhat’s Better for the Environment: Raising the Gas Tax or Fuel Efficiency Standards? Summary
3 Electric Vehicle History
1900sTimeline of Vehicle HistoryThe Timeline of Electric CarsUp to 1915Huff and Puff—Steam First, Then Electric, Then Oil, and Then Electric AgainThe Golden Age of Internal Combustion EnginesA World Awash in Oil After World War IITwilight of the Oil GodsElectric VehiclesForget Oil! Electric Cars Have the Need for Speed!National Electric Drag Racing AssociationThe Need for DistanceCasey Mynott Builds for SpeedThe Need for an AssociationWorldwideNorth AmericaEuropeLithium Ion Just Starts the EV MarketThe Need for Events, Cars, Books, and MoviesThe 1990s Until TodayRegulation in California9/11, Oil, and Our New Understanding of EVsGM’s Awakening—The VoltEVs for the Twenty-First CenturyNear-Future Trends for Electric DrivesElectric Mobility Still Is an Academic and International MoveTurnEEVE (Italy)Tesla Is Building Model X Electric Cars and They Are Selling Like Hot CakesSummary

4 The Best Electric Vehicle for You
EV Purchase DecisionsConversions Can Save You Money and TimeBuying or Leasing a Ready-to-Run EV Saves You a Lot of TimeEVs Have Some Big-Name BackersOther Cool Electric CarsThe Netherlands Is Building Its Own EVMitsubishi i-MiEVREVA Is Loved in the United Kingdom and India. It’s Selling!EV Conversion ShopsBuying a Ready-to-Run EV from an Independent ManufacturerConverting a VehicleConverting Existing VehiclesConverting Existing SUVs and Van-Type CarsEV Conversion DecisionsThe ProcedureElectric Car Motors II: The AC Versus DC Debate IllWhere AC Electric Motors Aren’t the Best FitHow Much Is This Going to Cost?AnalysisConclusion
5 Chassis and Design
Comprehensive Testing Under Way—and There’s More on the WayChoose the Best Chassis for Your EVKnow Your Options!Optimize Your EVConventions and FormulasIt Ain’t Heavy, It’s My EVRemove All Unessential WeightWeight and AccelerationWeight and ClimbingWeight Affects SpeedWeight Affects RangeRemove the Weight but Keep Your BalanceRemember the 30 Percent RuleStreamline Your EV ThinkingAerodynamic Drag Force DefinedChoose the Lowest Coefficient of DragRelative Wind Contributes to Aerodynamic DragAerodynamic Drag Force Data You Can UseShape Rear AirflowShape Wheel Well and Underbody AirflowBlock and/or Shape Front AirflowRoll with the RoadRolling Resistance DefinedPay Attention to Your TiresRolling Resistance Force Data You Can UseLess Is More with Drive TrainsDrive TrainsDifference in Motor Versus Engine SpecificationsGoing Through the GearsAutomatic Versus Manual TransmissionUse a Used TransmissionHeavy Versus Light Drive Trains and FluidsDesign Your EVHorsepower, Torque, and CurrentCalculation OverviewTorque-Required WorksheetTorque-Available WorksheetTorque-Required and Torque-Available GraphBuy Your EV ChassisEV Conversions The Other Side of ConversionHow to Get the Best DealAll-Over Aerodynamic Aesthetics
6 Electric Motors
Why an Electric Motor?HorsepowerDC Electric MotorsMagnetism and ElectricityConductors and Magnetic FieldsAmpere’s Law or the Motor Rule Electromagnets and MotorsDC Motors in GeneralDC Motors in the Real WorldArmatureCommutatorField PolesSeries MotorsBrushesMotor Case, Frame, or YokeDC Motor TypesSeries DC MotorsShunt MotorsCompound DC MotorsPermanent-Magnet DC MotorsBrushless DC MotorsUniversal DC MotorsAC Electric MotorsTransformersAC Induction MotorsSingle-Phase AC Induction MotorsPolyphase or Split-Phase AC Induction MotorsWound-Rotor Induction MotorsTomorrow’s Best EV Motor SolutionAC Motors: HiPer Drive by ElectroAutomotiveMotor RatingsTuningKeep It SimpleConclusion
7 The Controller
Controller OverviewSolid-State ControllersElectronic ControllersAC ControllersController ChoiceAn Off-the-Shelf Curtis PWM DC Motor ControllerAC ControllersToday’s Best Controller SolutionsZilla Controller (One of the Best DC Controllers for Conversions)EV Controllers Help to Dispel All Myths About EVs TodayAC Propulsion, Inc., to the Rescue—TodayAC-150 Gen 2 System: A Reliable Proven Performer for Passenger Car NeedsAC-150 Gen 3 System: For Next-Generation EVsTesla Controllers Use AC Propulsion TechnologiesSummary
8 Batteries
Metals, Salts, and Ions: Nature’s Sad Love StoryBuilding a BatteryThe CircuitAmperes Versus VoltsBattery AnatomyShapes and Sizes of Lithium-Ion BatteriesBattery FormatsAmpere-Hours and VoltageWiring in Series or ParallelC-RateFlat Discharge CurveThe Diamond in the Discard Pile: LiFePO4The ScandalThat Beautiful LiFePO4 CathodeMolecular LiFePO4Tinkering with the LiFe4 RecipeStumbling onto Something GoodGoing with the GrainImpedance and Fast ChargingEnergy Density Versus Power DensityPower DensityMother Nature’s Battery Management SystemThermal Runaway ExplainedBest Practices for Your LiFePO4 EV BatteriesBalancingBattery ManagementCoolingWarm Enough?ChargingBattery Box PlacementBattery Wiring Safety Tip—First StartupSummary
9 The Charger and Electrical System
Charger OverviewBattery Discharging and Charging CycleWhat You Can Learn from a Battery Cycle-Life TestBattery Discharging CycleBattery Charging CycleThe Ideal Battery ChargerCharging Between 0 and 20 PercentThe Real-World Battery ChargerChargePoint America ProgramThe Manzita Micro PFC-20The Zivan NG3Other Battery-Charging SolutionsECOtality Partners with Regency Centers at 19 Locations NationwideThe EV ProjectRapid ChargingInduction ChargingNissan and Nichicon Launched the Leaf to Home Power-Supply System with EV Power Station in JapanThe EV Power Station: SpecificationsReplacement Battery PacksBeyond TomorrowYour EV’s Electrical SystemHigh-Voltage, High-Current Power SystemLow-Voltage, Low-Current Instrumentation SystemDC-to-DC ConverterWiring It All TogetherWire and ConnectorsConnectionsRoutingGroundingCheckingSummary of the Parts
10 Electric Vehicle Builds and Conversions
Conversion OverviewBefore Building or Converting Arrange for HelpArrange for SpaceArrange for ToolsArrange for Purchases and DeliveriesBuilding or ConvertingChassisMechanicalMounting and Testing Your Electric MotorFabricating Battery Mounts Additional Mechanical ComponentsCleanup from Mechanical to Electrical StageElectricalHigh-Current SystemLow-Voltage SystemJunction BoxCharger SystemBatteriesBattery InstallationBattery Wiring12-V Accessory BatteryAfter ConversionSystem Checkout on BlocksFurther Improved CoolingImproving Heating TooNeighborhood Trial RunPaint, Polish, and SignOnward and UpwardPut Yourself in the PictureSummary
11 How We Can Maximize Our Electric Vehicle Enjoyment
Registration and Insurance OverviewGetting RegisteredGetting InsuredSafety FootnoteDriving and Maintenance OverviewDriving Your EV Running Out of PowerRegular DrivingCaring for Your EVBattery CareTire CareLubricantsChecking ConnectionsSafety InformationBefore Working on Any Electric MotorMotorsEmergency KitRecommendations for EV Mass DeploymentEV Update Conclusion
Notes
Index

Overview

BUILD, CONVERT, OR BUY A STATE-OF-THE-ART ELECTRIC VEHICLE

Thoroughly revised and expanded, Build Your Own Electric Vehicle, Third Edition, is your go-to guide for converting an internal combustion engine vehicle to electric or building an EV from the ground up. You'll also find out about the wide variety of EVs available for purchase and how they're being built. This new edition details all the latest breakthroughs, including AC propulsion and regenerative braking systems, intelligent controllers, batteries, and charging technologies.

Filled with updated photos, this cutting-edge resource fully describes each component--motor, battery, controller, charger, and chassis--and provides illustrated, step-by-step instructions on how to assemble all the parts. Exclusive web content features current supplier and dealer lists. Custom-built for environmentalists, engineers, students, hobbyists, and mechanics, this hands-on guide puts you in the fast lane toward a cost-effective, reliable green machine.

Build Your Own Electric Vehicle, Third Edition, covers:

Environmental impact and energy savings
The best EV for you--purchase trade-offs, conversion trade-offs, and conversion costs
Chassis and design
Different types of electric motors and controllers
Lithium EV batteries
Chargers and electrical systems
EV builds and conversions
Licensing and insuring your EV
Driving and maintenance
List of manufacturers and dealers regularly updated on website

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