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Planning Mercedes Sprinter y.2000+ conversion

6108 Views 8 Replies 3 Participants Last post by  Sprinter
Hello, everyone!

Donor Vehicles: Mercedes Sprinter Medium & Long Based Vehicles carrying 17 people - I guess total medium weight about 3500kg-4000kg(have to check). Relief: Hills, lots of them :( high% upward angle.

-Skill level with auto mechanics and fabrication:
-Little (Economist by profession)

-What level of performance you are hoping to get:
-Acceleration-base model or better;
-1)Urban Model: 70-75km/h, 20-25km range(which take about 40-45minutes due to traffic) with 40-60 minutes brake in a 8 hour working environment.
-2)Interurban Model:95-100km/h; 2 trips - 100km range with 3-5 hours brake time between them

-How much money you are willing to put into your project:
-As much as it is needed.
if possible to get separate components cost like batteries, controller, charger and so on.

-What parts you've already considered, if any:

I would like to consider well separated answers between these 2 models: Urban & Interurban.

Main Question: IS it possible and at what cost?

P.S. Need only cost of parts (preferably some EU/Russian/Chinese Manufacturers)

The standard gasoline engine models have a max. 243lbs*ft torque (330 N*m)
max power ranges: 65kw to 105kw
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Hi Sprinter,

Why 2 different models/designs?

Do you need 2 separate vans for different purposes?

That weight looks on the heavy side. Maybe 3500kg gross laiden weight. Probably closer to 1500kg empty.

Have you got a set budget or a bottomless pit of cash ready to throw at this!?

It's definitely possible. I think you are looking at about 25000 euros for the longer range.

With the power range stated, the size and weight of the vehicle and your preferred locations to source components. I'd consider the following components.

Kostov 11 alpha motor

Soliton 1 controller

I'm going to take a stab in the dark and say 400-450wh/ mile.

Meaning for 100 km range (62 miles) will need roughly a 35 kwh battery pack ( 10000euro plus)

Hope this helps!


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-Yes, 2 different vans.

- GLW of 3500kg in the Interurban model will always be reached. It is a passenger van, so I want to build the vans with "reserve". It should be 100% reliable, service disruptions won't be tolerated, as I will be the first who inserts EV in the public transportation. I can do calculations, so if you could help me with the formula's (last time I did physics was in high school).

-Well, I thought of hiring some polytechnic professors, to design the controller, dc-dc converter, charger... in such a case I'll do some cost cutting to the non-battery related components, motor not Included. Overall 20k euro's budget per van.

-Same idea here, does regen help a lot (AC system)? The roads are 50/50% hills.

One last question, seen the budget, what are the most reliable battery distributors or manufacturers?

P.S. Thanks for help Mike!
There's not really any set formulas you need to know the wh/mile. That can be calculated using the drag coefficient, crossectional area, weight and rolling resistance. The best way of calculating it is to see it in the real world!

Once you have the wh/mile you supply simply multiply by the number of miles and then divide by the % dod written as a decimal ( e.g. /0.8)

I'd buy everything off the shelf... That way you get a known reliable product, no safety concerns and you won't need to worry about stuff like EMC testing.

My opinion on ac is that it's an overpriced, underpowered technology and you are better off going for a more powerful dc motor and spend the extra on batteries. You can expect a 10% range increase at best with an AC system

As for batteries. The most suitable cells for this application are normally CALB or Sinopoly. Which country are you based in?


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