I'm actively working on converting an Insight along the same lines as Wayland's post, using Victor's small 18KW (1PV5105WS12) Siemens A/C drive, evercel NiZn batteries, and a PFC50 charger.
I'm starting with a Canadian Honda 2000 Insight with manual transmission with 12400 miles that magically appeared on ebay from a local dealer in Oregon the day of Woodburn drags. Almost as magical was the convergence of the very people I needed to consult at the Wayland juice bar the day after Woodburn. Thanks for answering my many questions! Here are the parameters for the insight. Wheel diameter for P165/65R14: 22.44 inches (my calculations match your 1.87 ft). Frontal area: 20.5 sq ft (can't find the source of this!) Drag coefficient: 0.25 ( http://www.plugitin.co.uk/insight_intro.htm). Donor curb weight: 1878 lbs (I have AC) (http://www.honda.com/../insight_factsheet.pdf) Batteries: 20 Evercel MB60-12-8 12V 66AH 36.4 lbs each total: 728 lbs, 240V, 66AH pack (http://www.evercel.htm/manufacturing.hmtl) Alternative batteries: 26 Evercel MB50-12-8 12V 42AH 23.1 lbs each total: 600 lbs, 312V, 42AH pack (same source) Another (too low voltage) alternative: 26 SAFT STM100-E NiCd 6V 100AH 29.04 lbs total: 755 lbs, 156V, 100AH pack >From page 2-10 of the Honda 2000 Service Manual: primary: 1.0 direct 1st gear: 3.461 2nd gear: 1.750 3rd gear: 1.096 4th gear: 0.857 5th gear: 0.710 reverse: 3.230 final: 3.208 Hope this helps with your calculations. Gary Victor wrote: =================================== Martin, I'd like to do performance simulation for Insight. In addition to gear ratios if you know, please provide: Wheel diameter (is is 1.87 ft? Frontal area m^2 (or ft^2) Drag coeff C_d (Isn't it 0.28 or so?) Battery choice and weight. 100Ah NiZn cell MB100 is actually 100 Ah, not 82 Ah. I'm not sure about weight. The motor is going to be 1PV5105WS12, in fact it already has been purchased for this conversion. 80 kW max 125 Nm (92 ft*lb) max @ 1000 RPM. I'm glad to see that gear ratios are very similar to CRX (after all Insight is a twin of CRX) so the sweet spot will be on the second gear - about 5,500 RPM @ 65 mph. Victor Martin Jackson wrote: > > Notes on John Waylands Insight EV > space alien green Insight with matching > Heat-rejecting green-tinted glass > est. price: $30,495 with air cond. EV-1: $ 35,000.+ with heat pump > home built $ 400-500 / month > "real world range of 130 miles" Est. Range: 79 miles combined > city/highway > > weight: 2300 lb. (est) EV-1 weight: 2970 lb. > (600 lb.of NiZn batteries) 1,175 pounds--or 40%--of that is > stock: curb = 1940 lb., 59/41 the battery pack > redline = 6000 rpm > EPA HP @ 50 = 7.1 > Insight is smaller, lighter > > Battery: 240 V of 30 lb. Evercell EV-1: Battery Pack: 26 VRLA PbA > NiZn MB-70 batteries modules (312-volt) > 65 ah at C/20 rate to 1.5VPC > 57.6 ah at C/1 rate to 1.3 VPC > 10.2" L x 6.65" W x 7" H > est. 65-80k mi. bat. life expectancy > > DC-DC converter, 75 A / 14.3 V EV-1: accessory module > supporting a 12 V battery 16.2 kWh/53 Ahr > > optional 192 V 16 Optimas > with the box removed > Nickel Zinc has full power even in > sub freezing unlike lead acid > powered EVs > These batteries are placed > (accessable) at the back of the > car, which is why battery care > is easy > > Siemen's 106 hp AC drive system EV-1: liquid-cooled induction motor > liquid cooled AC induction max. 102 kW (IGBT) liquid-cooled > motor & inverter power inverter, 3-ph > 1PV5105 WS12 for 92 lb.ft Power: 102 kW (137 hp) @ 7,000-13,500 rpm > 1PV5135 WS14 for 140 lb.ft ? Torque: 110 lb.ft) @ 0-7,000 rpm > (= 146 HP ?) > > vs. Hybrid > Horsepower @ rpm (SAE net / with IMA?) > 67 @ 5700 / 73 @ 5700 > Torque,lb.ft. @ rpm (engine/ with IMA) > 66 @4800 / 91 @ 2000 > The low-end torque from the AC > motor nicely avoids use of first > gear except in creeper duty. > > safe 10 k+ rpm with AC option > 0-100 mph in 2nd gear > 3rd gear 130 mph > 0-60: high 6 to low 7 seconds EV-1: 0-60 mph < 9 seconds > > optional 96 V sep-ex DC motor > > PFC20 on board charger plugs in EV-1: 110-volt/1.2-kW charger > anywhere, CA models need Avcon EV-1 requires expensive, > connector non-standard charge port > > fuel: normal 120 V or 220 > fast charged 1 hr. to get an EV-1: -15 hours using the portable > additional 60 miles of range > Wayland Signature sound system. > > The aerodynamic tweaks include > careful attention to under-body EV-1: full belly pans > airflow, removal of ICE allows > full under-body airflow smoothing > a 'teardrop' body shape with a 4.3" EV-1: nine in. narrower track > narrower track at the rear than the front > > covered-in rear wheels, EV-1: rear wheel skirts > a chopped-off tail. > drag: < 0.25 Cd EV-1: .19 with full belly pan > Mechanical and wind noise EV-1 "tyres pick up a lot of road > levels are low noise" > > The conversions instruments are EV-1: Displays and gauges are aligned > standard gauges, daylight readable along side of the windshield > There is a battery meter to the Center-mounted vacuum fluorescent > right of the speedometer which instrumentation > indicates electric charge or > discharge of the battery pack. > There are also a tachometer and > hot-cold coolant temperature gauge > > Regenerative braking is part of the EV-1: blended regenerative and > system. "Applying the brakes calls > for regen, and if the battery is > below 80 %, energy goes into the > battery. Four wheel anti-lock (ABS) anti-lock brakes > passive battery cooling assured by > battery heat capacity plus a fan > > Specifications > > Emission Rating: none > Redline (AC) 10000 rpm, EV-1: 13500 rpm > (DC) 5900 rpm > Front Suspension MacPherson Strut EV-1 Aluminum short/long arm > stabilizer bar 17.3 mm (2/3") > > Rear Suspension Twist Beam EV-1 Multi-link aluminum beam > trailing arms with Panhard rod > > Body Construction > Aluminum Hybrid monocoque body > Structural components and most body EV-1: Aluminum alloy structure > panels are extruded or die-cast SMC & RRIM Exterior Panels > aluminum; Front fenders & rear > fender skirts are recyclable > ABS/nylon composite. > > Insight's single body aluminum The EV1 is not a typical unibody > frame is 47 percent lighter than a car. It has a central backbone > comparable steel body yet it has frame, hollow to hold the batteries > better bending and torsional causing it to be wider and have > rigidity difficult battery access > > Interior dimensions > Headroom 38.8 in. > Legroom 42.9 in. > Shoulder Room 50.5 in. > Hiproom 48.7 in. > Cargo Volume 16.3 cu. ft. > Passenger Volume 47.4 cu. ft. > Exterior dimensions > Wheelbase 94.5 in. 98.9 (4/97 R&T) > Length 155.1 in. > Height 53.3 in. 50.5 > Width 66.7 in. 69.5 > Track (fr/rear) 56.5/52.2 in. > Ground clearance 5.9" 5.0 > > Tune-ups: none, weekly 'walk around' > And you never have to go to the gas > station > > Wheels: 14 x 5.5J Cast aluminum EV-1: 14-inch aluminum alloy > Tires: Bridgestone Potenza RE92 P175/65R14 Michelin� Proxima RR� > 165/65R14 78S LRR all-season radial at 50 psi > ftTiredia=(2*.65*165/25.4+14)/12 =(2*.65*175/25.4+14)/12 > =1.87 ft. =1.91 ft. > > Drivetrain > The transmission is a 5 speed > manual, with clutch pedal for > shifting. "When the car comes to > a stop, the car is off" > > { @ N=10000 rpm } > {pi*ftTiredia*N*60/5280/axle/g.r/ } > {3.14*1.87*10000*60/5280/3.208/g.r} {3.14*1.91*13500*60/5280/10.946} > {208.1/g.r } > 1st gear ratio 3.461 60.1 mph 84.1 mph > 2nd gear ratio 1.750 118.9 > 3rd gear ratio 1.096 189.9 > Final drive ratio 3.208 EV-1: Drive Ratio: 10:946:1 > > Variable-Assist Rack-and-Pinion EV-1: electric steering pump > Turning dia. 31.4 ft) curb-curb EV-1: 32.5 feet > > ABS Brakes > Front Discs 231 mm EV-1: 245 mm solid discs with > aluminum calipers > RearDrums 180 mm EV-1: 225 mm metal-matrix > composite drums, electric actuation > 60-0 = 153 ft 60-0 = 149 ft > ______________________________________________________________________ > 14 Jun 2001 (Siemens) > motors page at: > http://www.metricmind.com/motor.htm > _______________________________________
