[ausev] Fwd: [Open Manufacturing] Electric car parts

[Bryan Bishop]

---------- Forwarded message ----------
From: Alan Grimes <agrimes at speakeasy.net>
Date: Tue, Jan 6, 2009 at 1:04 PM
Subject: [Open Manufacturing] Electric car parts
To: openmanufacturing at googlegroups.com



There are many pre-fab parts in an electric car. One notable item is the
controller. The best controller, the Zilla is not on the market right
now because the inventor couldn't handle the stress of running a
company, it is, by far, the best though. It would be wonderful if it
were open sourced, but that's not today's subject.

There are two or three items in every EV conversion that must be custom
made for each model and battery configuration.

Problem 1: Battery racks. The battery racks must support batteries which
may weigh as much as 70 pounds each and integrate into the frame of the
car such that it mechanically sound and resistant to acid. This is both
a design problem and a fabrication problem, requires cutting of metal
parts and welding.

Problem 2: motor mounts: mounting the motor to the existing motor mounts
such that it is not subjected to excessive stresses, needs to handle
some of the load of a drive train capable of putting out upwards of
800ft-lbs of torque (taking gearing into account).

Problem 3: The adapter plate/bell housing. Must match the engine to the
existing gearbox/manual transmission to sufficient precision to make
sure that the motor is close to perfectly centered on the input shaft of
said gearbox, the companies that do this commercially usually request
measurements down to the thousandth of an inch.

Problem 4: The drive shaft mating adapter. It must link the standardized
output shaft of the motor with whatever the transmission has and be hard
enough to directly bear up to 250 foot-pounds of torque.


--
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