Ferrari 308 EV Conversion

1688 Views 13 Replies 4 Participants Last post by Samuel369, 2 mo ago

308GTE

Hello All!

I am in the early phases of converting my Ferrari 308 and am loving the content on this site! Super informative.

In university, I was captain of my college's formula hybrid racing team so I have experience building automotive mechanical systems from scratch as well as designing custom battery packs and power electronics systems . Hoping to bring a lot of the safety protocols from those builds into this conversion.

Some key specs of my conversion:
1. Donor Car: 1982 Ferrari 308 GTSI
2. Tesla Performance LDU
3. 16 Tesla Battery modules (85Kwh capacity)
4. The cool or "unique" aspect of my build is the custom Grounded Low Voltage System and Thermal Management System. The GLVS is a custom PCB that powers everything and acts like a watch dog that ensures everything is operating correctly / puts the system into a safe state if any critical errors are detected. The TMS is a custom Arduino based system that actively cools / heats the entire system. It is essentially a fancy Arduino shield that runs the complete thermal management system from a Model S in addition to the cars HVAC system.

The GLVS and TMS PCBs are done and now I am diving in to the mechanical part of this build! I plan on posting updates / questions as I inevitably run into challenges here and there.

Cheers,
308GTE

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X19e

· #2 · 4 mo ago

Hello 308GTE!
Welcome to the Forum and congrats that you started this project!
It looks like we have at least one challenge in common: choosing a Microcontroller to control parts of the functions. You've selected Arduino for the TMS and which one for the GLVS?
I didn't want to design a custom PCB and therefor I've searched for a board that already has most of the features I need. The result was this board: CANBed M4 Development Board with ATSAME51G19A MCU and MCP2542FD CAN Transceiver. It will control my original dash board, power two analog gauges (Tacho and Temperatur) and two Mini-OLED Displays which I use instead of indicator lights. It will receive the messages and values via CAN-Bus from Inverter, BMS, IMD and maybe Charger.
Let us know more details about the components you've choosen and the way they cooperate.

Best regards
X19e

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308GTE

Discussion Starter · #3 · 4 mo ago

Hello X19e!

For now, the GLVS is a fully analog board wherein I am using the 12v fault signals from the IMD(isocha425) BMS(Orion 2) TMS ( I have it output a 12v signal if a critical error has been detected)) to break the main contactor circuit if something bad has occurred and the car should be de-energized. On the GLVS board there are relays in series that are each controlled by one of the before mentioned systems. The contactors can only be closed once every system gives the "thumbs up" and closes its respective safety relay. Besides this safety function, the board acts like a fused 12v distribution/ control board for the rest of the car.

I decided to design my own TMS board (image of it below) so that I could use all of the TMS components off of a model S. Having worked on electric race cars in university(I graduated in 2018) I am keenly aware of the importance of a good TMS and figured it was worth the effort. The board uses an Arduino DUE as the "brain" and then has a series of Relays and mosfets that are capable of driving all of the Tesla components (pumps, fans, coolant Valves, Refrigerant valves, Ac Compressor, Battery Heater, Etc). The board is going to need a few tweaks based on initial testing but it seems to be a good plug and play solution for an active TMS. I am using a CAN trasiever that I got off of amazon but that will likely bite me in the ass - assuming it doesnt work I will replace it with something more reliable.

One planned upgrade to the TMS board is adding circuitry to run my dash cluster. I can pull a lot of the info from the ev-controls motor controller via can (speed, power, regen, etc) but also have analog 0-5v signals from the BMS for state of charge, discharge rate, etc. The TMS is going to need another board rev anyways so I will add this functionality after building and testing the TMS.

Cheers,
308GTE

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X19e

· #4 · 4 mo ago

I've got a similar relay-chain at the moment, but sometimes I thought that I would be more flexible with a PLC. Adding dynamic signals like 'stay on Brake" during start up would make a lot of sense.
Btw. you've designed are very clean board. Do you plan to integrate it into the dash or is the display only for diagnostic?
Next question: Do you plan to have remote access to your car? For Preheating or charge control?
Best regards
X19e

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308GTE

Discussion Starter · #5 · 4 mo ago

I agree re: the dynamic signals - once the car is working I would like to redo the GLVS system so that there is a controller deciding what is happening instead of binary on/off signals. The relay chain is simple and effective but it's an all or nothing approach. having the traction pack disconnect when a fault occurs is generally a good idea for safety but not if you end up stranded in the middle of a busy freeway.

This board is going to live in one of the electronics enclosures and that screen is just for diagnostics / debugging so I dont need to drag my laptop out to see what is going on. I plan on having it display some key info (pack temp, what state the system is in, error codes, etc). I plan on reusing the original dash cluster and having the car have a "sleeper" vibe where you dont know its electric by just looking at the interior. There will of course be tells like custom switches, etc but mounting an iPad in the dash is a no go for me.

I currently don't have remote access planned but that would be pretty easy to implement as preheating could be accomplished just by turning this board on and letting it do its thing. I will have the Tesla HV coolant heater in my coolant loop so preheating the pack shouldn't take too long.

-308GTE

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remy_martian

· #6 · 4 mo ago

"Tesla Performance RDU" - Model 3?

Or Model S LDU Performance?

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X19e

· #7 · 4 mo ago

We just had the discussion about signalling an IMD failure to external persons, e.g. rescue forces. I've seen that e-Motorsport requires Safety-Indicators for a 'Live' or 'Safe' system state. There are FIA regulations for it. Have you gained experience with this during your racing team time?
Wouldn't that be a mandatory requirement for us DIY electric car builders? Of course, this would only be of use if all the rescue organisations knew about it.

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308GTE

Discussion Starter · #8 · 4 mo ago

remy_martian said:
"Tesla Performance RDU" - Model 3?

Or Model S LDU Performance?

Apologies, that was a typo. I am using a Performance LDU off of a P90 Model X

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308GTE

Discussion Starter · #9 · 4 mo ago

X19e said:
We just had the discussion about signalling an IMD failure to external persons, e.g. rescue forces. I've seen that e-Motorsport requires Safety-Indicators for a 'Live' or 'Safe' system state. There are FIA regulations for it. Have you gained experience with this during your racing team time?
Wouldn't that be a mandatory requirement for us DIY electric car builders? Of course, this would only be of use if all the rescue organisations knew about it.

Yes, there were strict rules about fault signaling. We had to have a series of lamps that showed if the contactors were closed, if there was an IMD fault, etc. I have purchased panel mounted lights that will go on the battery enclosure that will serve this purpose. As of now I only have lights that indicate when the system is energized, when there has been an IMD fault, and when any of the inertia sensors have been tripped.

I had a buddy get stuck to an energized pack in college because he didn't know it was energized so signaling the system state is a must.

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remy_martian

· #10 · 4 mo ago

How'd he get unstuck? Am curious.

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308GTE

Discussion Starter · #11 · 4 mo ago

remy_martian said:
How'd he get unstuck? Am curious.

someone just ran and tackled him - definitely not the OSHA approved way to handle the situation but it worked

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remy_martian

· #12 · 4 mo ago

Pretty astute realization that he was stuck. Most bystanders don't know.

Did the tackler get a tickle - this has my curiosity piqued.

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308GTE

Discussion Starter · #13 · 4 mo ago

I dont think so? that tackler was wearing a thick winter coat and pants

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Samuel369

· #14 · 2 mo ago

308GTE said:
Hello All!

I am in the early phases of converting my Ferrari 308 and am loving the content on this site! Super informative.

In university, I was captain of my college's formula hybrid racing team so I have experience building automotive mechanical systems from scratch as well as designing custom battery packs and power electronics systems . Hoping to bring a lot of the safety protocols from those builds into this conversion.

Some key specs of my conversion:
1. Donor Car: 1982 Ferrari 308 GTSI
2. Tesla Performance LDU
3. 16 Tesla Battery modules (85Kwh capacity)
4. The cool or "unique" aspect of my build is the custom Grounded Low Voltage System and Thermal Management System. The GLVS is a custom PCB that powers everything and acts like a watch dog that ensures everything is operating correctly / puts the system into a safe state if any critical errors are detected. The TMS is a custom Arduino based system that actively cools / heats the entire system. It is essentially a fancy Arduino shield that runs the complete thermal management system from a Model S in addition to the cars HVAC system.

The GLVS and TMS PCBs are done and now I am diving in to the mechanical part of this build! I plan on posting updates / questions as I inevitably run into challenges here and there.

Cheers,
308GTE

Hello friend! I'm super excited to hear you're taking on a Ferrari conversion. My father is a vintage car expert, and I'm also a vintage car lover. It's amazing to see them given a new lease on life. And driving a Ferrari is our life goal! Right!! It sounds like you have tons of experience building automotive systems, which is great. Adding the Tesla Performance LDU and 16 Tesla battery modules is definitely going to give the car some serious power and make for an incredible driving experience. I'm particularly impressed with the custom grounded low voltage system and thermal management system you've developed; safety should always be a top priority when it comes to custom builds. Challenges will come up along the way, brother; it's part of the journey. You have a whole community to support you. All the best for your future challenges.

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