Electric Car Project

This project details the design and construction of an electric car.


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Last updated Thursday, 04-Dec-2014 20:59:23 AEDT

Status: Deferred Phase - This project has been deferred until the technology catches up.

I intend to keep adding information to this web site in order to formulate a workable design for an electric vehicle. The problem that I am finding is that there are so many options, interdependent variables and design constraints that any one component selection can lead to a dead end. Because of this, I am planning to develop a software application that can guide people through the process and take all of the variables into consideration. Please check back again to find out more.

Project Goals

This project seeks to analyse the costs and other issues associated with building an electric vehicle to use on Australian roads.

You should be able to use the formulas on this page to build your own electric car.

Collapsible Regions (please click for details)

What is an electric car?

Why an electric car?

Why EV is Still Archaic? From my research to date it has become obvious that the current state of EV technology is still resting in the dark ages, particularly in the area of energy storage.

The Ideal EV Technology So what would be the ideal combination of technology that will give us the quantum leap in cost and performance that we are all hoping for?

+ Safety - The No. 1 Issue

+ Electric Vehicle Links

+ Prototype Design

Let's get straight to the point and list some components and iteratively refine the selection and specs based on the requirements and research further down this page.

  • Approach - After reviewing Government regulations, it appears that the simplest approach is to take a commercial internal combustion engine vehicle and do an EV conversion. In most Australian States and Territories, an engineering certificate covering only the alterations and a check with the local registration authority gets you on the road with a fully registered electric vehicle. This is much simpler that starting from scratch and you already have most of the equipment installed and working before you start.
  • Where to Start? - This web page outlines an iterative design that make initial assumptions, fleshes out details and back-tracks to refine other associated details. I have attempted to break the design into logical top to bottom steps that should provide a template for others looking to do an EV conversion. All figures quoted show the calculations that lead to the value and links to supporting information are included whereever possible. Your selection of components will likely lead to a very different EV conversion.
  • Keeping It Efficient - Keep the tires pumped up, recharge often and clean out the boot.
  • + The Vehicle

    + The Motor

    + The Controller

    + The Energy Storage

    + The Charger

    + Power Steering Pump

    + Vacuum Pump

    + Auxillary Supply

    + Financial Analysis

+ Electrical Design

    This section provides details of the electrical components in the EV conversion including power, control and instrumentation.

    + Power Circuit Design

    + Control Circuit Design

+ Mechanical Installation

    This section provides details of the EV conversion steps.
    Note Because of the high voltages and currents involved, the work listed below is Dangerous and you should take all reasonable steps to ensure your safety. Never connect the battery to the rest of the circuit without access to a disconnect switch that is capable of disconnecting a short circuit (900A+).

    + Preliminary Bench Testing

    + Remove ICE Components

    + Mount the Electric Motor

    + Install the Battery Charger

    + Install the Controller

    + Install Battery Bank

    + instrumentation Design

    + testing Design

    + registration Design

    + ontheroad Design

  • Auxillary Support - all of the following items are taken for granted in a petrol based vehicle and are supplied from excess mechanical or electrical energy from the petrol engine. In an electric vehicle, additional electric motors and/or power supplies are needed.