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Discussion Starter · #1 ·
Hi :) I'm a complete newbie to this electric conversion business. So some of these questions might show my ignorance.

Just after some advise, i have the opportunity to buy a newish remy hvh250 motor for $650 dollars, i will have to make the housing for cooling. I'm a CAD draftsman by trade and have worked in the engineering sector for 15yrs and use soildworks and inventor, I also have a friend with a company that uses water jet cncs so can help me out in that area too, so not to worried about that. I'm i right in thinking this is a brushless motor? and AC not DC?


What I'm after is some basic info on whether this motor might reach a top speed of 80mph - 90mph comfortably if used within a van / camper, I can add gearing of course. The rpm of the motor and torque seem to suggest it will. The vehicle i want to convert is an oldish volkswagen camper van, its quite a large heavy long wheel base one with popup roof. Hopefully when the engine is removed and with batteries and electric motor installed it will be approx 3500kg in weight.

The other question is it seems to be all about what voltage is put through the the motor to achieve higher speeds, so basically that means a lot of batteries. I have been looking at CALB LiFePO4 ones for there safety and longevity. They seem to be 210ah with a 3.2v so would i need a hell of a lot to get a a decent voltage to power the motor. So if i had 30 of these I'd get 96 volts? - I have read about people putting 700 volts through a similar remy motor?.. is this achievable with batteries or would that be via another power supply?

The last thing is to utilize this high voltage do i need an expensive controller like a rinehart or can i use a cheaper curtis controller like from a forklift truck? I'm guessing what i'm looking for is a controller that can handle a high voltage?

A lot of questions at once but thanks if anyone can tackle any of them!
:confused:
 

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Discussion Starter · #3 · (Edited)
Thanks for the reply madderscience, yes i have been researching the hybrid batteries from salvage vehicles and think this is the right way to go as they have higher voltages. upto 7.2v some of them. I think I will have to go nimh route initially because I can get them much much cheaper, which also helps! I could poss get upto a 100kw+ pack in the van. I want the vehicle to use for my daily commute at first which 22 miles to and from work, then i can improve on it for mountain biking trips. At the moment it is sat on my drive without an engine as i was planing a TDI conversion, even bought the engine but not having a change of plan. The engine cost me £1200 so :/

I'm in the UK i put the figure of the motor in $ because i figure most people on here are from US. 3500kg an estimate with batteries and loaded camping gear. The van is a eurovan style over in US. Its called a transporter type 4 in the UK. The vans the gross vehicle weight rating is 2890kg. But i have just read that the unladen weight is around 2000kg so 3500kg might be an over estimate.

Also in my thoughts was to add solar panels to the roof as it is quite large and also opens upwards at an angle. Is there any point in doing this or is adding solar panels a fruitless operation?

Oh the 80 - 90 mph speed was just for overtaking in emergencies on the motorway not a constant velocity, manly if i was to use the motor way i would obviously keep within the 70mph speed limit!
 

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Discussion Starter · #5 ·
Ah! yeah i see what you mean solar wise, maybe for off grid camping TV / fridge etc then.

I have purchased the Remy HVH motor now, nothing ventured nothing gained!

Controller wise there are a few of these curtis ac controllers second hand for relatively little money are they
man enough for the job think these are for forklifts so probs low mph voltage?

https://www.ebay.co.uk/itm/Curtis-M...414267?hash=item2f0d687c3b:g:FmUAAOSwehZZ7IL1

These are my other battery options then opposed to NiHM

https://www.ebay.co.uk/itm/Toyota-P...377406?hash=item3d49c0cdbe:g:-qUAAOSwYyVZewW3

Lithum ion prius batteries approx £700 savaged - maybe 2 or 3 of these £2100

https://www.ebay.co.uk/itm/Tesla-Mo...325925?hash=item1c96842125:g:-4EAAOSwTm9Z-Esw

Tesla Module salvage £800 maybe 2 or 3 of these £2400

When you said tesla battery did you mean a module or the entire 16x modules?

Nissan Leafs battery is abit out the question as these are £4500 30kwh

https://www.ebay.co.uk/itm/2015-NIS...095489&hash=item4645935b85:g:y~0AAOSwAPlXg4fC

As for volt / vauxhall ampera cant find any of those yet

Could an DC/AC inverter / charger system be used from one of the salvaged vehicles or are they to integrated within the system of the vehicles to operate as a standalone unit?
 

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Discussion Starter · #10 ·
Thank you for the reply Brian, I have opted to buy one of these AC Control/Driver boards from PandSpowerelectronics in Canada and build my own controller unit.

https://pandspowerelectronics.ecwid...rol-Driver-Board/p/59121602/category=16287307

This PCB is pretty impressive the board contains all the controls and 6 isolated drivers for driving a 3 phase AC induction or permanent magnet motor at powers in the 200-300kW range. It is designed to be plugged right into 3 IGBT half bridges rated up to 1200v 600amp.

It needs a resolver to encoder converter PCB add on though.

Now to figure out getting enough power through it!
 

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Discussion Starter · #11 ·
The spend for the electric motor project so far:-

£500 for the motor
£300 for the Motor controller PCB
£100 for resolver to encoder converter PCB

£?00000 Batteries we are talking thousands right!

Here is the van in question link to build Build thread, quite a lot of work has gone into it already hand modified the electric elevating roof
and there was a lot of welding work on the floor, there is a lot of space for batteries under the floor so considering cutting away recesses to house them
and re welding and strengthening

http://www.vwt4forum.co.uk/showthread.php?t=241503&page=3
 

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Discussion Starter · #13 ·
Yes i think you are right, not sure where i got Canada from..

I'm researching 18650 batteries, they are pretty common for E-Cigarettes if i could find a wholesaler that supplied them at £1 a battery i could be on for a winner. I found some one who recons them for £1.40 but not ideal
 
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