| Owner | Bernard Mentink | ||
|---|---|---|---|
| Location | Christchurch, Canterbury New Zealand map | ||
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| Vehicle | 1995 Holden Calibra This car is also branded Opel Calibra or Vauxhall Calibra. It is the low drag co- efficient (0.26) 8-Valve version. | ||
| Motor | Asea Brown Boveri Industrial Motor 3GAA 131 008-HSE 3-Phase AC Changed tack on the motor yet again, Finally decided on this 140kw peak, 350Nm peak motor that does better than a lot of motors designed for the EV market. It is a little on the heavy side at 91kg, but not overly so .. | ||
| Drivetrain | No gearbox. Will mount a 3:1 ratio independent diff from a V8 Holden Commodore to the front axial and drive directly with the motor. | ||
| Controller | Custom Will use the KiwiAC STM32 based controller feeding a Skiip 900v 200A Semikron power module. The KiwiAC module includes an isolated 3 contactor interface. The software running on the controller will be open source code from the Tumanako site. Doing it this way gives me full control of the motor algorithm ... after all, you would not buy a car you could not tune yourself .. would you? | ||
| Batteries | 448 Headway 16A/H, 3.20 Volt, Lithium Iron Phosphate The motor/controller combo is capable of 900v DC ( running at bus of 716V leaving plenty of headroom for regen), I am using 224x2p arrangement for the cells. As these cells are capable of 10C continuous, that equals a total of 160A x 2 = 320A continuous available if I need (however the controller is limited to 200A) Normal use (0.5C, only couple of amps per cell) should be very good for the life of the cells. E.G: 8 amps per cell = 8x2 = 16A x 716v = 11.45Kw = ~16Hp On the other hand peak horsepower = 200A x 716V = 143.2Kw = 191Hp (minus losses) | ||
| System Voltage | 716 Volts | ||
| Charger | Elcon TCCH-312-5.5 x 2 I will use two chargers, each one will charge 1/2 the pack. | ||
| Heater | No plans yet. | ||
| DC/DC Converter | Meanwell HLG-240H-15A Going to use a small motorcycle battery for my auxiliary 12v supply and use these 240VAC/15VDC LED lighting power supplies to keep it charged and supply aux power, they are rated to 277VAC so handle 400V input fine, and I have found that the output voltage adjusts down to 13.8V just fine with an output current of 15A. They are rated at 225W and are current and voltage limited. I will use two of these, each one across 1/2 the pack with the outputs in parallel. | ||
| Instrumentation | Will make my own that interface to the controller that will display system parameters. Also will use two existing meters on the car as ammeter and voltmeter. | ||
| Top Speed | 100 MPH (160 KPH) Initial trial will be at 1/2 pack voltage of 362V so top speed will be approx 110Km/hr, running at full 716V, I expect top speed of 160Km/hr | ||
| Acceleration | Will let you know .. | ||
| Range | 100 Miles (160 Kilometers) My aim is to commute to-from work, round trip of 60 miles, so going to design it for 70% DOD at 100miles. My design calculations show a 160km range(100m) based on weight and kw/hrs. | ||
| EV Miles |
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| Seating Capacity | 5 adults | ||
| Curb Weight | 2,640 Pounds (1,200 Kilograms) 1200 kgs Starting kerb weight, hope to reduce it down to 2200 lbs (1000kgs) | ||
| Tires | Going to re-fit with low profile ones and pump them up hard. Also add solid hub caps. | ||
| Conversion Time | So far it has taken 10 months, but mostly because I had to wait 9 months for the motor to arrive. Lead time is the killer! | ||
| Conversion Cost | Aiming for < $25000 New Zealand including donor car. | ||
| Additional Features | Will have under-body streamlined to reduce drag when finished. | ||
| History: -------- ---------April-2011---------- Ordered ABB motor ---------June-2011----------- Removed ICE, gearbox, muffler, tank etc from car. ---------Aug-2011------------ Got drawing made of motor->gearbox adapter plate done. ---------Jan-2012------------ Changed tack on the drive coupling. Now going to direct drive motor to a diff mounted to the front wheels (decided I had enough spare torque to not need the gearbox). Just scored a 900V 200A Semikron Skiip power module off Ebay for $220US, this will form the basis for my controller, so have upped my pack voltage to get some more horses out of the motor .. I am buying the batteries last, and will fine tune the optimum battery voltage 1st. I should be able to do the complete 180Kw capable controller for around $1200NZ now, the alternative for me was the Tritium controller at $8000NZ, so a BIG saving, and I can run at double the voltage ... yay .... ---------13-Jan-2012---------- After 9months delivery time, finally have my motor from ABB,and the Semikron power module is on it's way, once I purchase some DC link caps and the contactors, I will be able to test bench. --------- 20-Jan-2012--------- The Semikron Skiip power module has arrived. Once I have received the DC link caps and the contactors, I will begin bench testing at 36v. --------- 27-Jan-2012--------- January has been a productive month. My DC/DC converter and the DC-Link caps have just arrived. --------- 21 Feb-2012--------- Completed initial bench test with 36V Bus voltage, motor accelerated very smoothly to 3000 rpm. Now to rob some more car batteries to test at higher voltages. Will use this time to fine tune the software on the KiwiAC controller, space-vector modulation together with slip control works and IFOC (Field oriented Control) is a work in progress .. when that is completed, it will be the preferred control method. ---------- 6 April-2012 --------- Commodore V8 independent diff and motor are being mounted on the sub-frame complete with rubber mounts. The whole lot will be lifted up from the bottom of the car and bolted in place. Finished mounting the Hall-effect throttle assembly .. hopefully in a couple of weeks will have the wheels turning :-) ---------- 17 Oct-2012 --------- Have the motor finally connected to the wheels, see latest photos .. I have heaps of space to mount controller and control gear, that is happening next .. | |||
1995 Holden Calibra
“eCALIB”
(under construction)
Last Updated 10-17-2012
Copyright © 1997-2024 by Mike Chancey