[Scobie1knobie]

Dear all,
I am looking to convert our 1970 Fiat 500L into an electric town car, and having undertaken quite a lot of research I have tentatively dipped my toes into the EV pool with the first acquisition- this being a Dana TM4 IPM 200-50 low voltage permanent magnet ac motor. Performance wise the motor is apparently capable of 20kW peak power at 96 volts. The only data sheet I can get from Dana shows its performance at 48 volts with a corresponding peak power output of 16kW with a peak current draw of 450 Arms. Torque is 70 Nm at 48 volts. For comparison, the ICE powered performance figures for the 650ccengine version are 24bhp (18 KW) and 41 Nm torque. I am pretty happy therefore that the Dana motor should be adequate to at least match or improve on the ICE performance.
I am currently working up designs for adaptor plates and couplings to mate the motor to the existing gearbox, flywheel and clutch.
My next purchase, unless you all tell me the motor is a dud, is to purchase an inverter/controller. To this end I have researched Curtis controllers, but they are not cheap!
Does anyone have any suggestions for an inexpensive 3 phase 450Amp peak controller, or perhaps a working used one that someone is looking to recycle?
I like the idea of an open source controller but my electrical/electronic skills are pretty much non existent so it would have to be plug and play. I am also very happy to use used parts from a salvaged EV, but not sure which vehicles would be suitable to look at.
For batteries I am thinking of using second life Nissan Leaf Gen 2 modules hooked up in series to produce 72-96 volts. Range I am looking for is a real world 60 miles.

Any and all thoughts/contributions will be great fully received.

I am at the very start of this journey so please excuse my ignorance.

Many thanks

Scobie

 

[Scobie1knobie]

Hi Markus
Many thanks for your speedy input. Yes, I believe the motor should be fine. Dana do produce inverter/controllers but don't generally sell to individuals, so I may have to go third party. However I was hoping that a Curtis or similar would be able to speak to the motor as an alternative. Not looking for fancy programming or advanced control, but rather simple voltage and current control and possibly regen braking
With regards to the gearbox and clutch I'm not sure if the rpm range of the electric motor will suit without some gear ratio changing so will probably stick with using the clutch and gearbox. In reality I'm sure I will probably just leave it in second gear for around town driving and perhaps move up to third gear for higher speeds.
Happy to post progress pictures as and sketches as I progress.
Thanks again

 

[Scobie1knobie]

Thanks for your input Brian.

 

[Scobie1knobie]

Hi Brian
Yes, that is the, correct data sheet.
The 450Arms will be the peak current draw.
My initial calculations for a vehicle range of 60 miles based on 100Ahour batteries suggests 72volt battery pack, so I am looking at 10 modules of second life Nissan Leaf Gen 2 batteries as that pack in series will give me the voltage required and fit neatly into the space vacated by the fuel tank. I can probably accommodate another 1 or 2 modules so can get the voltage up to 96 volts.
So my most pressing issue is to source a 96volt, 450 Amp inverter controller. Dana produce a suitable one called the AC-M1but as I mentioned don't sell to individuals, so looks difficult to obtain. I'm sure Curtis have a suitable controller that I could use, but wondered if there are any alternativs that I should be thinking about?

 

[Scobie1knobie]

Hi Brian
Yes I did look at different combinations of volts and Amphours as you have suggested, and from a size and form factor and cost perspective the Nissan Leaf modules work pretty well. Given how small the motor is I could split the pack and locate some batteries in the current engine bay also which would help lowering the centre of gravity and mass distribution. As I mentioned I am right at the beginning of the journey so still lots to work out. Once I have a better idea of al the various component sizes I will do a mock up to see how it all fits. I have researched Curtis controllers a bit further and have found a current spec model which I think would suit, this being the AC F6-A. So I think that is a suitable option.
Thanks again for all your input.
Cheers
ScobiBTW which part of Canada are you in?

 

[Scobie1knobie]

Dear all
Many thanks for your input. It's all useful to me.
I know many of you have commented on battery options, but to be honest my biggest issue is finding a suitable inverter/controller for the motor. And also the programming of the controller.
In the grand scheme of things the battery options are pretty straightforward to resolve.
Do any of you more experienced EV gurus have any ideas to solve the controller conundrum?

Again, any and all suggestions will be gratefully received.