EV Conversion - Part 2


12/9/2008 - The charger, watthour meter, timer and cable reel installed

27/9/2008 - The first of the 5 battery sub-packs being assembled.  The black straps tie the pack together and prevent the cells from swelling unacceptably if they get too hot.  This should not happen if they are to last their specified design life.  I hope to avoid having to actively cool them but will not know if this will be necessary until I have tested the system in the real world.

29/9/2008 - A drawing of the battery box showing main power wiring.

29/9/2008 - The first of the 5 battery pack sub-packs with balancing PCB attached and wiring started.

10/10/2008 - The gearbox/motor adaptor plate fixed to motor.

23/02/09 - The motor/transmission coupler...

23/02/09 - The centering tool (above and below) for aligning the transmission adaptor plate with the centre of the gearbox input shaft prior to drilling the attachment holes.  This ensures perfect alignment of the motor and gearbox to prevent noise and wear on bearings etc..

25/05/09 - With the help of friend and colleague Ade Sell - an ex-toolmaker, we have mounted the gearbox on the adaptor plate with centering tool (not visible) in place, ready for marking the fixing holes.  We have already knocked out  the 2 locating dowels from the gearbox bell housing (see below).

25/05/09 - This is one of the dowel holes with a bush inside it ready to poke a drill bit through to mark the hole position.

25/05/09 - The RPM gauge in action (right click and play).  The motor speeds up too quickly to see the effect but once at max speed you can see 3 darker patches at the innermost ring which, when the power is disconnected, move outwards and increase in number as the motor slows down.  Each ring represents an rough RPM.  In the video the blobs appear at the innermost ring which represents 2400RPM.  Unfortunately this gauge is designed for use in the US where the mains is 60Hz.  Here in the UK it’s 50Hz so I must apply a correction factor - but at least I know I’m not over-revving the motor.  More than 6000RPM and it might explode (mind, it needs to get very hot too for this to happen!).

25/05/09 - The dowel back in place ready to mate the adaptor plate to the gearbox.

25/05/09 - A device for getting an idea as to the speed of rotation of my motor whilst testing it with 12V - using a mains fluorescent bulb as a ‘stroboscope’ (courtesy of Sherline Lathes)

25/05/09 - The bush mentioned above, from the other side.


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