Development of a low cost battery electric car based on a 1996 BMW 316i

• Top speed : 75mph
• Range (lead-acid battery) : 30 miles
• Range (Lithium battery) : 100 miles
• Fast recharge (30 to 60 minutes)
• Transmission : Clutchless manual
• Power steering , vacuum assisted abs brakes , cabin heater
• Battery fuel gauge
• SMS charge status messages
  
• Regenerative braking
• Optional tri-fuel range extending trailer
• DC compound wound traction motor
  

I wish to thank Mr.Jim Tracey and the team at JTM Power for ongoing assistance with this project.



Vehicle development is chronicled in the following videos. Mistakes and misadventures included!

The Motor :




The Gearbox to motor adapter plate :





Electric motor installed in car :



Electric brake vacuum pump.
An electric car has no engine and hence no source of vacuum for the brake servo.
 A 12v pump is used instead :




Electric motor mounts , brake vacuum system and charger socket:



Motor controller development:











First test runs at 24v using two old batteries to prove the concept:





Development of a high power intelligent switch mode charger for the car:







Here we see the new adapter plate and motor to gearbox coupler:





Test Run of the newly installed drive train at 24v:



Charger system installation:



Running the drive train on my new odyssey batteries. Redline time!!:



Progress update and quick hill climb test:



First practical use for the ev!:



Quick progress update :



Video of the commutator taken on a 1.2 mile drive to pinpoint brush arcing problems :



Procedure for advancing the brushes in a DC Motor to reduce brush arcing due to armature reaction :












Test Drive of the EV Part 1:



Part 2 :