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A day of engineering

A project log for DIY Electric Vehicle from Recycled Parts

Converting a car to electric drive using recycled and salvaged EV and hybrid components.

mauswerkzmauswerkz 12/14/2015 at 03:140 Comments

The guy helping me with the mechanical work on my project is sick today so I spent the day working on other parts of the project. The first part of the day was spent with my BMS board. I got it to measure the pilot signal from the EVSE, respond correctly to pressing the button on the handle, and command the EVSE to turn on. That all works as desired, which was very exciting. Seeing the LEDs light up on my EVSE telling me that it was connected as a really cool moment. I also spent some time developing the state machine layout for the BMS. This will help me write it. It's fairly complex, 9 states.

I then turned to my trusty spreadsheet and fine-tuned the weight and balance. Here's a plot from my spreadsheet-o-calculations. Shown on the axis is the location of each mass added (or modified in the case of the 12v battery and seats). The axles are also on the plot.

I still need to decide whether to keep the entire 32kWh of batteries and simply not charge them to full in order to keep the voltage below where it needs to be. Since there's relatively little capacity seen above the "knee" of the charge profile, I would get a net increase in capacity as well as extend the usable life of the cells, but I need to find where the sweet spot is as far as charge voltage and capacity.

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