Optimization of a 1974 VW Optimization of a 1974 VW Electric BugElectric Bug

Michael BoyleMichael BoyleMichael LaBeachMichael LaBeachAndrew MagalettiAndrew Magaletti

Rabei RabeiRabei Rabei

ProjectProject

ProblemsProblemsHillsHillsSpeedSpeedRangeRangeLightsLights InteriorInterior

Project SpecificationsProject Specifications Increase TorqueIncrease Torque Increase SpeedIncrease Speed Increase RangeIncrease RangeDistribute WeightDistribute Weight

Design ConceptDesign Concept Battery CageBattery Cage 24V Field Charge24V Field Charge Battery ConfigurationBattery Configuration Rejuvenated BatteriesRejuvenated Batteries Heat Sinks on Heat Sinks on

ControllerController Air Induction for MotorAir Induction for Motor Hydrogen VentilationHydrogen Ventilation

Battery CageBattery Cage DesignDesign

Material Material CostCost Efficiency Efficiency

Battery Cage AnalysisBattery Cage Analysis

Battery Cage Stress AnalysisBattery Cage Stress Analysis

Stress AnalysisStress Analysis Displacement AnalysisDisplacement Analysis

Battery ConfigurationBattery ConfigurationAddition of 6 Addition of 6

batteriesbatteries Increases rangeIncreases rangeSeries/ParallelSeries/Parallel

Field Voltage PackField Voltage Pack Increases speedIncreases speed Increases torqueIncreases torque

Range - CalculationsRange - CalculationsRange Calculations

RangeEnergybattery

Energyused

mile

I1 260A hr 20 Ah capacity x 2 for parallel configuration

Cf .57 Conversion factor from Trojan website

Vpack 72V

Ebatt Vpack Cf I1 Eused 200W hr

mi

RangeEbattEused

Range 53.352mile

Speed - CalculationsSpeed - CalculationsActual Top Speed

Factoring rolling friction give us a better estimate of the top speed.

P12

air Vc3

Af Cd Vc Fr

Fr r Wcar Fr 125.92N

Vc 60mph 61mph 75mph

Ptest Vc 12

air Vc3

Af Cd Vc Fr

Ptest 70.14mph( ) 15kW

Varying the V value in the above equation, a top speed of70.14 mph can be reached with a 15kW motor.

Power vs. Velocity

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

18.00

20.00

55 60 65 70 75 80

Velocity (mph)

Pow

er (k

W)

Battery RejuvenationBattery Rejuvenation Rob MatthiesRob Matthies ProcessProcess

Analyze BatteryAnalyze Battery Recondition BatteryRecondition Battery

Rejuvenation ProcessRejuvenation ProcessAnalyze BatteryAnalyze Battery

Determine discharge rateDetermine discharge rateNatural voltageNatural voltage

Rejuvenation ProcessRejuvenation ProcessRecondition BatteryRecondition Battery

Use a battery reconditionerUse a battery reconditionerShake batteryShake batteryCharge, Discharge and RepeatCharge, Discharge and RepeatGood BatteryGood Battery

Heat SinkHeat Sink Regulating Regulating

Controller Controller TemperatureTemperature

Motor Air InductionMotor Air InductionKeep motor cool Keep motor cool

at 96Vat 96VSize of fanSize of fan

Hydrogen VentilationHydrogen Ventilation Fan Size Fan Size Fan MountingFan Mounting

Cost AnalysisCost Analysis

Conversion ManualConversion Manual

ConclusionConclusionSpecifications metSpecifications metUnder BudgetUnder Budget

Future PlansFuture Plans Battery revivalBattery revival

Shaker TableShaker Table Order PartsOrder Parts Heat Transfer AnalysisHeat Transfer Analysis Finalize Cage DesignFinalize Cage Design

ReferencesReferences Brant, Bob. Build Your Own Electric Vehicle. TBA Books, Blue

Ridge Summit, PA. 1994 “Evalbum”, (11/6/08), www.evalbum.com Barkley, Michael.(9/10/08) “Mitsubishi Eclipse Conversion”,

(TexomaEV.com) http://www.texomaev.com/ (Accessed: 9/26/08)

AcknowledgementsAcknowledgementsRob MatthiesRob MatthiesDr. HollisDr. HollisAndrew ParkAndrew ParkMichael BarkleyMichael BarkleyDr. ClarkDr. Clark