Charging at workMeasuring motor and transmissioncoupler to interface transmissionIGBT stack Motor and tranny bolted togethermotor mountedRear pack
OwnerEric Tischer
LocationDublin, California US map
Web/EmailWebPage email image
Vehicle2001 Volkswagen Passat
4 door
MotorSiemens Siemens motor built for Ford Ranger EV 3-Phase AC
90kw water cooled 3 phase AC Motor
DrivetrainStock 5 speed manual.

I designed the motor coupling and adapter plate myself.
Controller Tischer AC90 with torque control
I built the 3 phase controller myself. It is running in
closed-loop vector mode, which allows control of torque and
speed.

My AC90 controller draws 300a @ 300vdc (330vdc pack with
some sag under load), about 120 hp.

Water cooled IGBTs

Batteries99 Thunder Sky 100 Ah LiFeYPo4, 3.00 Volt, Lithium-Polymer
System Voltage330 Volts
ChargerManzanita Micro PFC20
If I can keep the charger cool, I can recharge at about 16 miles
per hour (26 amps @ 208 volts). The charger is only rated for
20 amps though.

HeaterHeated leather seats. Ceramic heater core installed in the
cabin air filter box.
DC/DC ConverterIota
55 Amps at 13.4 with the ignition relay off, 14.3 volts with
ignition on.
InstrumentationThe industrial inverter I am using came with a 2 line LCD
key pad. It can display motor load, torque output, motor
amps, dc bus voltage...

-100 to 300 amp ammeter, I can peg it in both directions.

I also replaced the dash clock with a 2 line lcd. The
tachometer and LCD are run with an Arduino.
Top Speed105 MPH (168 KPH)
105mph on flat ground verified by GPS
Acceleration0-60 is 14 seconds using only 2nd gear

It will easily break the front wheels loose in 1st gear.
Range100 Miles (160 Kilometers)
The farthest I've taken it is 70 miles, but based on the battery
capacity, it should do 100.
Watt Hours/Mile350 Wh/Mile
Typically 40 miles = 40Ah = 320 whr/mile
Keeping a light foot I can do 40 miles with 35Ah =
300whr/mile
EV Miles
Current:33,565 Miles (54,006 Kilometers)
 
    As of 3/18/2012
Seating Capacity5 adults
Curb Weight3,700 Pounds (1,681 Kilograms)
actual weight without driver. Previously, I had 25 Optimas,
the car weighed in at 4010 lbs.

Installed custom rear springs to prevent sagging in the rear.
Tires4
Conversion Time1 day per week for 9 months
Conversion Cost$30k so far.

$2k was for air conditioning.
$12k was for batteries
$2.5k was for the charger
$1k for cable, lugs, angle iron
$1.8k was for the car
$1600 for my Siemens motor
$800 for machine work
$3000 for parts to build my inverter.
Additional FeaturesI'm using a Magneflux compressor for air conditioning.

Electric power steering using a Renault Kangoo electric pump and custom hydraulic
hoses.

My home built inverter is proving to be 100% reliable, 33k miles an no issues!

code by jerry