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CTECHI is an expert in battery solutions, specializing in ODM, OEM, and SKD for energy storage, motive power, and consumer batteries.

electric vehicle - a simple lightweight ev platform

Chassis is one of the few items you need to make.
Most items are sourced from the chassis and connected to the chassis.
We use a pressed aluminum box made of 3mm thick aluminum sheet as the main structure spine and battery box.
This method makes manufacturing very simple, maximizes rigidity, reduces weight, and concentrates in the center of the car, avoiding damage to the battery pack during impact.
One of the disadvantages of using thin-walled box sections is that large concentrated loads cannot be applied directly to aluminum walls.
It is easy to overcome by using tubular steel sub-frames or partitions to disperse the load.
The steel pipe frame is relatively small and difficult to make.
The box needs a lot of pressure to bend.
Since this is a simple box, your local metal roofing supplier should be able to provide materials that are cut and pressed in size. .
I purchased a box 3 m long, made from a 1, 270mm x 300mm high and wide.
Sheets for 2 m x 3 m x 3mm and cover is $300.
The box is wide enough to hold 4 batteries, plus a thin lining.
Laying the lining helps protect the battery and prevents any drum passing through the chassis, ensuring that the rivet head does not rub on the side of the battery.
Connect the lining to the aluminum chassis using a sikaflex car or marine polyurethane flexible sealant/adhesive.
Please note that the lip on the aluminum box can not only be used as a place to fix the lid, but can also strengthen the structure when the lid is not fixed in place.
A series of aluminum blocks or laying plates are installed inside the chassis.
The partition has many functions.
They support the Box box from bending, supporting the battery that accelerates and slows down the load (
Including impact)
It also provides reinforced installation points for heavy parts such as motor, seat frame or floor.
The box also needs a lid that can be opened to touch the battery, but it needs to be securely secured as a whole structural part of the box.
While the rivets will provide fast and powerful accessories, it is not suitable for the testing and development requirements of custom vehicles.
A suitable alternative to using rivets is to use rivnuts and socket screws.
Rivnuts and screws are available from 6mm to 8mm.
Their spacing should be reasonably close and since the threads are easy to combine, stainless steel nuts and screws are not recommended.
I used 6mm socket screws at 50mm spacing.
I do not recommend the use of stainless steel socket screws and rivnuts as I have learned the hard way when several socket threads are combined and need to be drilled out for replacement.
The graphic showing the box size of the box is shown above, as well as the Autodesk Inventor rendering showing the basic chassis layout.
The box is designed to optimize the 45 CALB 100Ah lithium battery with four widths.
The external subframe sliding on the part of the box is used to install the suspension.
The sub-frame is welded from 25mm x 1.
6mm steel box section.
They are connected to the aluminum box using structural rivets inside the box.
The angle attachment of the drill or right angle drill is crucial for drilling the rivet hole, which requires the pneumatic rivet to apply enough pressure to set the Structural rivet as you are not suitable for the large manual rivet in the box.
Structural rivets used to connect the frame of the pair, such as giant rivets.
In Australia, they may need to purchase from professional suppliers such as Profast.
At the time of writing this report, the supply of structural rivets on Ebay is limited, but suppliers such as Profast will release the supply.
Starting from under $100, pneumatic rivets are available online and require higher pressure to set up structural rivets, especially in confined spaces.
The front and rear subframes mounted on the box are shown above.
The hanging installation point can be seen in the photo.
The angle of the external component matches the suspension bracket.
The car uses two motors to be mounted on the subframe on the chassis to drive the rear wheels through the belt.
There is a fixed speed and keep the belt (or chains)
Keep the inside of the chassis clean, minimize maintenance and protect the fingers.
This platform can easily adapt to almost any motor installed on the face or foot.
I use 58 kg AC motors per unit.
Their size is a good price with good torque in a wide range of RPM.
The BLDC or permanent magnet AC motor will provide higher weight power, but the equivalent power output at this size will be more expensive due to the cost of large rare earth magnets.
My AC induction motor comes from the power supply of the electric vehicle and comes with a controller.
The Brush Motor is a more economical option, and the Etek/Mars type motor like Motenergy ME0709 costs about $600 per unit.
The motor also needs the motor controller.
I\'m not going to go into detail here on the choice of motors and controllers, as there are other good resources available, but most motor suppliers will offer motors with controllers or will recommend the appropriate controller options.
The dedicated motor controller designed for the vehicle drive system has a forward and reverse design and often regenerates the program.
They also typically have switch inputs compatible with 12 v ignition switches for turning on and off the controller.
Connecting the motor controller is as complicated as installing the after-sales audio on the car, although you need to be very careful not to make mistakes, otherwise there may be smoke and tears.
Power is passed to the rear wheel through the tooth belt.
The 30mm wide gate GT3 will transmit peak power up to 30 KW and operate smoothly and silently.
The chain drive can be cheaper and lighter and provide a higher torque rating.
The use of a belt or chain drive eliminates the need for a gearbox, as the motor has sufficient torque for single-speed operation, especially for light-weight vehicles.
I am using two AC motors with a torque combination of 300Nm and a gear ratio from the motor to the rear wheels of 3: 3, while the acceleration from the rest is very good, it is currently oriented at a very high maximum speed, so better low range performance can be achieved through a lower gear drive.
The rear shaft of the rear shaft includes two half shafts that are bolted to the original Mazda drive shaft.
A large pulley is mounted directly on each half shaft and is driven by a small pulley mounted directly on the motor.
The half shaft is supported by the basic bearing at both ends, about 20mm of the inner bearing and 30mm of the outer bearing size, and the pulley is mounted on the shaft.
The chart above illustrates the post-Axel arrangement.
The half shaft has an external flange welded to the shaft and is machined to match the rear drive shaft flange of the MX5/Miata.
There is no interconnect between two drivers or Motors-
Each drive is completely independent of the other drives.
The torque properties of the motor are inherently allocated torque between drive wheels, so no differential is required.
This arrangement will also promote the simple development of real control systems in the future (
Torque vector)HOW TO. . . .
Order the motor and controller of your choice order a small pulley or sprocket with holes and keyway to drive the belt or chain after order pulley with a matching ratio of 1:3 and 1:5 motor order.
It is easy to change the ratio and experiment, and the best ratio needs to take into account the motor selection, target speed and acceleration properties.
A taperlock bushing is usually required for a larger rear pulley.
This makes it easy to install the pulley firmly on the transmission and change the pulley ratio in the future.
The only item specially machined in the transmission system is two half shafts, one end of which has a flange to accommodate the drive shaft flange of the suspended body part.
A large rear pulley or sprocket is installed on each half shaft, supported by each end of the bearing connected to the box and the rear suspension subframe.
Each side of the box is equipped with an aluminum-pressed floor box and a 25mm x 1 Rivet.
The 6mm square hollow steel pipe extends to the chassis before and after the floor box to help spread the load to the end of the disk so that the Rivet Joints on both sides can work together.
Alternatively, the frame of the floor box is suspended on the box of the machine and placed on the rubber pad, making it more suitable for interchanging modular components and providing additional shock absorption for smoother driving.
It is essential that, since there is a considerable load in the event of a collision, the passenger unit must be well connected to the chassis.
For direct rivet floors, a large number of rivets share the load, providing considerable shear strength.
Where the floor box frame is used together with several connection points of the box, the reinforcement of the chassis box will reduce the risk of local bending or tearing of the chassis box at the sub-frame connection point in case of higher speed impact.
The photo shows a layer of finish on the top of the floor box.
In this example, a layer and aluminum composite floor box are used.
The composite panel is constructed by rivets and bonding a layer and aluminum sheet on the aluminum rib and foam core.
This increases the stiffness, reduces any \"drum sound\" on the floor and provides a good finish.
It takes more time to make, but can reduce the cost of the material because the ply is very cheap and it allows the use of lighter specifications of more expensive aluminum.
The seat shown is the Jaz Pro blow molding juable seat.
Lightweight and affordable, ideal for outdoor use. .
A vehicle platform was developed for the installation of a double crossarm suspension on each wheel and rear drive.
The crossarm suspension provides maximum flexibility in both body design and driving height, because the crossarm provides simple height adjustment, usually requiring lower wheel height than the support suspension.
When driving the rear wheels, the crossarm also provides the best handling performance, a little simpler, avoiding the need for CV joints on steering wheels, and providing more interesting handling.
The rear wheel drive is also suitable for more centralized placement of the motor, so that the best placement of the heaviest parts closest to the center of mass of the vehicle.
The cheapest and easiest way to get a suspension part is to get it from a vandalized vehicle, but there is a limited number of front and rear crossarm and rear wheel-driven vehicles.
Mazda MX5/Miata and Honda s2000 are two vehicles that are quite light in weight.
Since Mazda MX5 is more common in Australia, I used a crashed Mazda MX5.
The suspension of the MX5 is conveniently attached to the subframe, which can be removed from the car by removing some bolts.
The sub-frames include all suspension mounting brackets so they can be reused, but the box needs some work to cut and install around the original sub-frame, so it\'s simpler (and lighter)
The way is to make your own front and rear subframes and connect the suspension, wheels, hubs, brakes, springs, etc.
Done on the new sub-framework.
Photo: the rear and rear wheels removed from the MX5 and the suspension are shown in the above photo along with the original front and rear subframes.
Note that the front suspension subframe is quite heavy as it also includes the front engine bracket.
In the last photo, the newly made subframe can be easily seen on the car.
Although the MX5 is a light-weight car, there is still a lot of unspring weight, with four wheels, brakes and suspension assemblies weighing about 140 kg in total, about 1/3 of the weight of the car.
Lighter weight (
But more expensive and fragile)
From Formula Ford parts suppliers, aluminum racing wheel columns and hubs with prefabricated crossarms and pole ends can be purchased. HOW TO. . . . .
First of all, if you need to disassemble the host car to remove the parts, please refer to a useful guide such as how to remove the MX5 body from the manufacturer of the exocet kit car, although the suspension part can be easily removed by removing the cross arm pivot Bolt at the rear and the drive flange bolt as well as the cross arm pivot Bolt at the front.
Secondly, press the support of the suspension pivot from the steel plate 50mm wide x 3mm thick.
The bracket width needs to match the width of the inner end suspension bushing of the cross arm.
They may need to be slotted in order to adapt to the external inclination adjustment.
Mazda uses a simple offset washer to position the suspension mounting point in the slotted hole for surface adjustment.
Third, in the middle of the adjustment range, attach the bracket to the hanging arm.
When the suspension and wheel are still assembled, fix the bracket on the suspension mounting sub-frame and check the position and route of the wheel.
Clamp long-length pipes onto the wheels to help them align.
Once the wheels are in place and aligned, fix the mounting bracket on the suspension sub-frame with a welder, then remove the hanging arm and weld it in place.
The bogies are located at the front of the chassis, and two tubes or angular arms are welded to the front suspension sub-frame to install the rack.
The angle of the steering shaft and column needs to be determined to accommodate the seat position in the car.
The position of the rotary joint on the steering column bracket is suitable for the highly adjustable steering wheel.
Mazda CAD online provides useful information 3d CAD drawings for Mazda MX5/Miata suspension assembly, which can be used with free 3d CAD programs such as Autodesk Inventor Fusion for the development of suspension design.
Mazda bogies with power steering have higher (faster)
Ratio of non-auxiliary racks.
Since the weight of this vehicle design is lighter and no hydraulic assist is required, the auxiliary rack can be easily disassembled.
Instructions for canceling the MX5 bogies are available online on the MX5/Miata community forum.
The experience of driving and fine-tuning light electric vehicles designed around a central battery box is much simpler than that of a petrol powered car.
Basically, it is to plug everything in, check that the motor is running in the right direction, fine tune the two throttles, tighten the drive belt, and there is almost nothing else to do other than that.
The concept of dual motors driving two rear wheels independently works well, and the motor torque and speed features automatically assign power to both rear wheels without the need for an \"electronic differential \".
During the adjustment of two separate throttle tanks, some drift occurs, and they send signals to their respective motor controllers.
This will not cause problems during normal driving and will be resolved in the future by using an electronic split. going back to a throttle tank.
The electric car is used around a farm with a small tray that proves convenient, smooth and quiet, and the short trips around the farm are typical and the battery pack does not discharge under 85%.
The large cross-section size of the chassis box provides excellent stiffness without visible wear and the design will continue to be tested on rough farm roads to demonstrate the strength and reliability of the concept to expose any weaknesses.
The performance level of the motor is far beyond what can be explored on gravel farm roads, and some tracking time needs to be booked for further performance testing in the future.
The gravel field track does provide a good test ground for testing the torque vector system to achieve optimal performance on smooth gravel roads, and plans to develop future projects for Arduino-based torque control systems, though not responding to current Arduino challenges in a timely manner.
The range, speed and recharge time update the typical energy consumption of 0 in May 2014. 74Ah/km (106wH/km)
, Normal driving, gravel road.
It uses about 1% of battery power per kilometer on unsealed farm roads and off-road roads, equivalent to 100 km or 60 miles per charge.
For my application and testing, the range is much more than required around the farm, and the package is also larger in size to ensure a safe peak current consumption exceeds the range.
The advantage is that the additional packaging capacity provides a mobile power supply around the farm.
For farm tracks, the speed is too fast and there is no upper limit to explore the speed range, which will have to wait for track time.
On a tree-lined farm track, I will not exceed 100 km/h or 60 mph.
It is estimated that the maximum speed is about 160 km/h or 100mph, but depends on the aerodynamics of the body, because the good low-end torque of the car is oriented towards the maximum speed of 200 km/h (
1: 3 motor and drive ratio, motor speed 6000 rpm)
Although it will not be able to reach such a high speed without a low drag, streamlined body.
Plan to reduce the gear ratio and increase the speed of acceleration to 100 km/h, which is faster than needed.
The charging time is about 5 minutes per 1% charge, or 8 hours from full discharge using a 10 amp 240 V single-phase battery charger.
The charging rate is not linear, and the charging rate drops as the battery approaches full charging.
D cad file, November 2, 2013, PlansBotEV chassis platform (dwg)
CAD file for chassis box section (dwg)
Motor, controller, battery and battery management-3D CAD model information and partsEV Power (Australia)
Small motors for light electric vehicle projects can also view cyclone motors, gold motors and Kelly control drive pulses and belts-
Gates GT3, Busselton bearings, aluminum pressure-
Combined metal industry seats for Jaz Pro
I would like to thank Rod Dilkes from EV Power for their encouragement, support and help.
Rod is the brain behind the electrical setup of this project.

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