[Elegancec]

Hello,

I read many articles in this forum and in my opinion it is very good.

At first I want you to introduce to my project, I want to convert a BMW Z3 from 1998. I have seen several motors which could fit and some which are not strong enough.

The BMW has now a maximum torque of 168Nm at about 4500rpm. At 1-2000rpm it has 120Nm. I want to have this performance again after installation.
At first I thought to use a AC-50 System with curtis controller, but this system only has 110lbft this is about 150Nm at maximum. But if you read it correctly, it has only 120Nm in normal condition if the batteries are weak in voltage. So this systems seems to be too weak for this car because you can only go up to 3000rpm without weaking of the torque.

A better choice would be the Siemens 1pv5135 series with the 50kW version. This has a water cooling and has about 160Nm and I think 330Nm peak. This would fit ideally but the costs... 5900€ at hec-drives.nl
This seems to be too much.

Piktronik has a very good controller for about less than 3700€ (see data beneath). So if I use this one, I need a good motor attached to this controller.

Do you have some suggestions?

80kVA Motorregler für Fahrzeuge und Boote

Batteriespannung: 96 V bis 290 V
Nennleistung: 80 kVA
Max. Leistung: 120 kVA
Motornennstrom: 240 A
Motorspitzenstrom: 280 A
Schutzart: IP54
Kuhlung: Flüssigkeit

HAUPTMERKMALLE
Innovative technologie
Kompakte bauform
Einfache Inbetriebnahme
Geberlose Regelung
Drehmoment- oder Drehzahlregelung
Sollwertvorgabe über CAN Bus
Autotuning und Selbsttestfunktionen
Batteriemanagement
Flüssigkeitskühlung
Technische DatenBatteriespannung 96 V bis 290 V
Betriebsspannungsbereich 80 V bis 340 V
Nennleistung 80 kVA
Max. Leistung 119 kVA
Motornennstrom 240 A
Motorspitzenstrom 280 A
Schutzart IP54
Kuhlung Flüssigkeit
Bemaßung 300 x 155 x 245 mm
Gewicht (inkl. Kabeln) 13 kg

ZUBEHÖR
Kabelsatz C60D6
Pumpenkabel C40P2
GD2-12V - Anzeigegerät

[somanywelps]

People used 11"ers.

[Elegancec]

Hi,

thank you for your post.

You're right, that would be the easiest conversion, but I think in Europe it would not be accepted from everybody.
In my opinon I have to use the energy from Regenerative Braking, because of the little capacity from the battery system.
So an Sepex or better AC system would ideally fit. The components I have suggested seem for me to be the best for this project.

[somanywelps]

Sepex and AC are limited on the options, specifically power.

How many HP and nm did you want?

I don't think you're going to want to pay that much for regen.

[zsnemeth]

Originally Posted by Elegancec

Hello,

A better choice would be the Siemens 1pv5135 series with the 50kW version. This has a water cooling and has about 160Nm and I think 330Nm peak. This would fit ideally but the costs... 5900€ at hec-drives.nl
This seems to be too much.

Piktronik has a very good controller for about less than 3700€

5900+3700= 9600 Euro

11" Kostov Alpha 2200 Euro

Soliton1 + EMC kit 3000 Euro

So, You'll have 4400 Euro battery or beer money....

[steven4601]

A Z3, brilliant choice if I may say so!

If im not mistaken, an isolation test is carried out during type approval. If you use a virgen dc motor (no dust etc) you'll probably pass the isolation tests. However, if you use a motor that has some miles on it, it is likely to fail the isolation tests. (Isolation of 200 Ohm per Volt is required. 2mA leakage maximum). The 100-ohm per volt requirement usese battery voltage. Example: a 220 Volt pack would require 220kOhm isolation or better between the traction pack and chassis.

If the dc / sepex motor is new, it will pass the isolation test. Otherwise it will be very doubtfull.

[somanywelps]

Originally Posted by zsnemeth

5900+3700= 9600 Euro

11" Kostov Alpha 2200 Euro

Soliton1 + EMC kit 3000 Euro

So, You'll have 4400 Euro battery or beer money....

The alpha would be a good choice due to the forced air cooling:

295A 500A
100nm 194nm
0.4585365853658537x + -35.26829268292684

312ft*lb per 1 @1000A
624ft*lb per 2 @1000A
177ft*lb per 1 @600A
354ft*lb per 2 @600A
143ft*lb per 1 @500A
286ft*lb per 2 @500A

[Elegancec]

Hello, thank you for your answers!

I think in comparison to the price and performance, there is no way not to use a DC system. So I have a question to the kostov 11 Alpha motor.
You can read on the controller homepages from netgain or zilla 1000A or also 2000A. So this is the maximum amperage rating what the controller can deliver.
If I look at the chart from the motor, round about 680A ->280Nm. So I think this is what somanywelps also stated in his previous mail.
So at 1000A -> 312ft*lb = 422Nm. I think the BMW would fly with this So my next step is to clearify how much torque the gearbox can handle.

Attached the interpolation.

[somanywelps]

Originally Posted by Elegancec

Hello, thank you for your answers!

I think in comparison to the price and performance, there is no way not to use a DC system. So I have a question to the kostov 11 Alpha motor.
You can read on the controller homepages from netgain or zilla 1000A or also 2000A. So this is the maximum amperage rating what the controller can deliver.
If I look at the chart from the motor, round about 680A ->280Nm. So I think this is what somanywelps also stated in his previous mail.
So at 1000A -> 312ft*lb = 422Nm. I think the BMW would fly with this So my next step is to clearify how much torque the gearbox can handle.

Attached the interpolation.

Yes it would fly, I'm working on planning an E46 conversion.

The gearbox torque rating is a potential problem. Valerun has been running his E46 conversions with the stock, 300nm rated gearboxes at 484 nm out of a Warp 11HV at 1000A from a Soliton 1 without any issues except the clutch (he stated the stock ones slipped, not sure what he replaced it with).

BMW transmissions have a reputation for being strong, and even BMW runs them over "spec" (see E39 M5 with an S6S-420G transmission).

A cursory look at realoem shows the 2.5 and up Z3's as having a 320nm rated gearbox, and you'd be peaking at 427nm (K11A @1000A with Soliton 1), so you'll be fine (I think).

You may need to replace the clutch with something that can hold on against that much instant torque.

[Elegancec]

Question about Solution 1 controller:

The website states 9-340V DC output.
The Kostov 11 Alpha wants 240V. So in my opinion the controller makes a pwm signal of it. So the battery system has to provide 250V, is this correct? So its not possible to use an 100V battery pack as an example?