Motor controller in the 2e?

[CyberBill]

Does anyone know what the motor controller used in the 2e / SO-1 is?

I know they're using the Remy motor - but I don't know what they've got for the motor controller, or if they built something in-house. Does anyone have any ideas?

The only reason I ask is because I'm trying to determine if an average guy could put together the entire drive-train that is used in the Aptera. I'm also wondering how similar the Leaf's drive-train is to Aptera's, seeing as they both have 80kW electric motors of the same basic variety from my understanding (brushless DC).

As it is, you can go out and buy a Remy motor, and a Borg Werner transaxle, and a big pack of A123 batteries, and pop them onto the frame of a small car, and you've got yourself a really nice electric vehicle... The only thing missing is the motor controller.

If you really had a lot of free time you could design the frame and body to your own liking, whether that means a CarBEN or a Bailey Blade or use it as the base for a kit car like a Pantera or a Ferrari knockoff. It just sounds awesome to me!

[evmavin]

Originally Posted by CyberBill

Does anyone know what the motor controller used in the 2e / SO-1 is?

I know they're using the Remy motor - but I don't know what they've got for the motor controller, or if they built something in-house. Does anyone have any ideas?

The only reason I ask is because I'm trying to determine if an average guy could put together the entire drive-train that is used in the Aptera. I'm also wondering how similar the Leaf's drive-train is to Aptera's, seeing as they both have 80kW electric motors of the same basic variety from my understanding (brushless DC).

As it is, you can go out and buy a Remy motor, and a Borg Werner transaxle, and a big pack of A123 batteries, and pop them onto the frame of a small car, and you've got yourself a really nice electric vehicle... The only thing missing is the motor controller.

If you really had a lot of free time you could design the frame and body to your own liking, whether that means a CarBEN or a Bailey Blade or use it as the base for a kit car like a Pantera or a Ferrari knockoff. It just sounds awesome to me!

After about 300 hours and $50K you may have an EV. If you really want to build an EV join the EVDL list as there are many builders there and they can share inverters on the market being used today. Or, wait for something on the open market and save yourself the pain.

[chris22104]

I've often thought about such a conversion with one of my first gen honda insights (the perfect donor car in my opinion.) I've read a number of books on ev conversions and talked to a few of the experts too. 1800 lbs stock, .25cd (lowest production cd next to the ev-1,) low rolling resistance tires, motor adaptor plate already available on the market, etc. No need for a transaxle; bolts up to standard trans. The big thing is the lifepo4 thundersky pack, and especially a bms. I don't mind the time involved. I've priced all the components and true the cost would be over 35k easily to do it right; hence my waiting to see what comes on the market and the reviews once out.....But you're right about the complete package; if you bought a wrecked (totaled) aptera in the future, and gutted it to transplant into such a small lightweight donor car, you may be able to do it on the cheap(er) and have a great, well matched (hopefully; to be seen) proven system. Regarding your specific question, I feel the Zilla 1k controller is the best by far (but production has been suspended for now, as the company is being sold I believe....)

[Stunt Driver]

I've done a budget convertion myself to see how things are, and I agree - to make a proper, highway speed, and at least 60 mile range car - will be above $20k even before you get to spend time on body. Leaf is perfect for the money compared to convertions.
So I've done myself a low speed commuter car to get my 5-7 miles to work and back, and waiting for Aptera. Or Leaf maybe.

[PatQ562]

Doesn't Azure Dynamics sell both motors and companion controllers? Their technology is at least "fair". And check with Flux Power, who provides a medium voltage (more DIY friendly) high power battery pack and BMS system, and may be able to advise on motors.
Pat Q

[Mesuge]

Conversions make sense only if they offer for your manhours/money something else, the OEMs can't/willingly refuse to deliver at the moment. So, if you are about superaerodynamic envelope or supersport package, you can try some of the existing racing kit cars, others might like real offroaders (not 4x4 SUV pretenders) - very heavy with limited range might not be an issue for some though, etc. Similarly, if you can't justify the (nonsubsidized) price for the econoboxes like Leaf, you can go with lower speed, short range conversion based on even smaller donors still. I gather most peple are into it primarily, because they are tinkerers at heart, and it rarely makes sense in terms of the overall cost of ownership, costs per mi, the enviro footprint etc.

Btw. contrary to your statement, you CAN'T go out and buy the automotive grade A123 (or LG Chems), that's OEM exclusive and/or very limited butique racing/conversion shops only.

Chris, gen1 Insight is just a perfect donor (one of the best cars ever anyway), if you don't mind two seater setting. I guess in that exceptionally light and aero. package you can easily go with low voltage (~120V) AC Curtis drivetrain and smaller batt. pack (sub 15kWh) and cut that proposed budget almost to a half, or hope for the P&S opensource AC controller, which is now in prototype stage, and cut the budget well bellow half that number you posted. In most of the other donors (with the exception of <<1ton kitcars) this won't work as satisfactory 1:1 ICE replacement though, and you will need "bigger guns" and higher budget.

[NeilBlanchard]

Another improvement that can be done on the Insight (or other cars) is to add a tail extension:





This is being built by "3-Wheeler" who is a fellow on Ecomodder.com, and he obviously has some kewl skilz! Here's the thread, starting with the conceptual renderings, all the way through to the pictures above:

http://ecomodder.com/forum/showthrea...ect-13533.html

I'm guessing that this increases the FE of the already impressive Insight by ~15%, or more! His 80.5MPG 90-day average could go up to 92MPG; which is impressive, indeed.

If the Insight was a pure EV, and had a aerodynamic enhancement like this (he plans on adding wheel strakes behind the rear wheels), then it would rival the Aptera for efficiency.