New project car

I found a 2010 Golf Variant which had an E-license. This Golf is one of 45 build by ECE, the same company which converted the Lotus to EV. Unfortunately al the EV part where removed. So basically we bought a body with a registration number (licenseplate).

I contacted my EV repairshop if they could restore the car with original parts. I everything goed as planned the Golf will run end of January 2018

06-JND-2

2010 Golf Variant 06-JND-2

Engine bay

2010 Golf Variant 06-JND-2 enigne bay

ChaDeMo diagnostics

So far I wasn’t able to fast charge my test pack. First I thought it had to do with fact that the JLD505 wiring was somewhat different than the schematic in the ChaDeMo Kit Manual because it has been used in a Zero motorcycle. The logging showed that the High voltage contactor was closed and that the EVSE supplied a high voltage. But after a few seconds the voltage rose to the max battery voltage set in the JLD505 and the EVSE stopped the charging process. Based on the ChaDeMo charging sequence flowchart I came to the conclusion that the JLD505 is working fine. But the test pack is probably causing problems. The test pack has old batteries from an UPS and they weren’t designed for fast charging.

Adjustable regeneration and regenerative braking

The amount of regeneration can be adjusted by supplying a voltage between 0 – 5V to the PEU. ECE decided to fix the voltage, at a safe level, with two resitors (2K2 and 3K3). I want to be able to adjust the regen,. E.g. in rainy conditions reduce the regen and in summer when using the Yokohama’s A048 increase the regen. I did some testing and it is unbelievable how much braking force is available when set to full regeneration.

 

regen-dail-frontview

Electric V50 test drive

Totday I went for a test drive in a 2010 Volvo V50. The V50 was converted by All Green Vehicles (AGV) for a Dutch project “Rotterdam test electisch rijden“. I was surprised by the build quality. AGV did a very nice job in integrating the electric system into the Volvo.

Volvo V50 electric

Volvo V50 electric

The interior is almost unchanged, the gauges in the instrument cluster are replaced with AGV designed gauges. They look like OEM.

Volvo V50 gauges

Volvo V50 gauges

Only two things didn’t work, the cruise control and the board computer. The clutchpedal has been removed.  Under the hood many thinks changed.

Volvo V50 UQM controller

Volvo V50 UQM controller

From left to right, UQM DC DC converter, UQM SR218 controller. In front there is part of the batteries.

Volvo V50 trunk

Volvo V50 trunk

CV joint difference

The inner joint of the early model (A120D4004F) has a fixed ball-type CV joint and the new model (B120D4004F) has a Tripod Plunging Joint.

The fixed ball-type consists of an inner ball race, six balls, a cage to position the balls, and an outer housing. Tracks machined in the inner race and outer housing allow the joint to flex. The inner race and outer housing form a ball-and-socket arrangement. The six balls serve both as bearings between the races and the means of transferring torque from one to the other.

Tripod plunging joints consists of a central drive part or tripod. This has three trunnion fitted with spherical rollers on needle bearings and an outer housing (sometimes called a tulip because if its three-lobed, flower-like appearance). On some tripod joints, the outer housing is closed, meaning the roller tracks are totally enclosed within it. On others, the tulip is open and the roller tracks are machined out of the housing.

Old and new CV joint

Old and new CV joint

..

Fixed Ball-Type Joint

Fixed Ball-Type Joint

..

Tripod Plunging Joint.

Tripod Plunging Joint.

Broken RH driveshaft

Last night I hit a speed bump and broke the RH driveshaft, i was putting my foot down quite hard in second gear. The back wheels did spin a little.

IMG_20160622_211010I stranded 500m from my home

IMG_20160622_182440

My wife was so nice to tow me home.

Towing

Towing

I asked the dealer which driveshaft would fit my Elise, they quoted the original driveshaft for an 2009 111R at €946,- with partnumber A120D0018F (#2).

A120D0018F

Driveshaft drawing A120D0018F

Due to the electric converison the original driveshaft can’t be used. It has a bracket (#11) that is attaches to the original engine. So I had to find out which one would fit my Elise.