How CAD and Simulation Helps Your ELECTRIC VEHICLE CONVERSION!
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- เผยแพร่เมื่อ 26 ก.ค. 2024
- How hot do batteries get? Do we need to cool them? What are the options for the electric powertrain? Do my components fit? How far can I go? Learn about how simulation and design can help you build your own electric car before you go out and buy the wrong components.
This is an overview of the design and simulation work we have done so far and there is much more to come. In this video you learn about our electric Jeep design concepts, how hot our batteries get during operation and how this affects the cooling system and how the electric range is affected by different real world driving scenarios. Hope you enjoy!
Simulation tools used in this project so far:
- Solidworks for CAD Design - electric powertrain concepts my.solidworks.com/
- Hexagon Cradle for 3D CFD - cooling plate design, thermal management www.cradle-cfd.com/
- MathWorks Simulink for 1D vehicle simulation - electric range, efficiency, thermal management www.mathworks.com/products/si...
Models and simulation available on my website soon!
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00:00 Electric Vehicle Conversion Electric Jeep
02:04 Where do Components Go? Space Claim Analysis
03:20 Electric Jeep Concept 1
04:25 Electric Jeep Concept 2
05:28 Reusing Batteries for Electric Jeep - Reconfiguration
06:57 Design Batteries in Solidworks
07:46 Battery Thermal Management, Active Liquid Cooling System
08:50 Cooling Plate Design
09:32 How Hot do Batteries get?
10:14 Electric Driving Range of an Electric Car. How far on one Charge?
11:53 More Questions?
🎵 𝗠𝘂𝘀𝗶𝗰
Outro - "Tropic Fuse" by French Fuse - ยานยนต์และพาหนะ
That's a first little overview of our design concepts and simulations, more to come soon! Let me know what you would like to see and what could be helpful for your project!
I cant wait to turn my 1978 jeep wagoneer electric.
Wohoo, have fun! 😊
@@ElectrifiedVeronika Thank you, so far I have one person supporting me haha!! I will!
Thanks guys! A lot of builders will scratch build and figure it out on the go but there is also many of us playing with Fusion etc and want to design more optimally before we move forward. This was a lot of help. Keep going!
Thank you!! We will definitely share more CAD and simulation work very soon, so glad this is helpful!
The way you broke down the modules to single parallel rows (I assume) is brilliant. Can't wait to see more.
Thank you - AND we did not hurt ourselves - not yet anyways. - but really you have to be careful in case you want to do that - but yes, the flexibility once you have the slices is cool!
This makes me want to buy a 99 jeep just like yours and follow your steps LOL.... not sure I could ever do what you are doing but I would love an electric Toyota Tacoma-sized truck
Of course you can! 😊 Where there's a will there is a way 🙌🔋 Yesterday we started a collaboration with a local Jeep workshop, with the idea that in the future people can bring their own cars and get professional help with the conversion where they need it. We are also thinking about offering a training course to get people up to speed and prepare them for the conversion of their dream car. Let's see 😊
@@ElectrifiedVeronika those are fantastic ideas
Wow! I am highly impressed by your simulation work. I am a Swiss car engineer and got a BsC in electronic engineering and soon want to convert MY dream car, a C3 Corvette! 🙂
Thank you! Wish I could do more - would need a couple more people for that, but so far it really helped us along to decide which option to choose. Greetings to beautiful Switzerland!
Super informative:)
Thank-you for another great update on the Gilmore Girls Electric Jeep. Love seeing the enthusiasm and updates on this project. Keep up the great work. 🙂
Thank you, I hope to get "Luke's" attention at some point - and maybe Lorelei and Rory want to stop by too for a ride hehe.
I’m a Jeep fan and owner, as well as a Mechanical Engineer and designer, and this series has been so fun.
It intrigues all the scientific approaches, in the correct order or operation I might note, and then just makes me smile to see something like the Jeep Wrangler that is so familiar and close to home, go through a very original design change and perhaps Future Proof design.
I’m happy to see in your other comments that you are working with Jeep shops, which was going to be my suggestion, as those places have likely seen motor swap, tub and chassis modifications, and axle setups that will greatly add to your toolbox of knowledge.
Good luck! If you find yourself coming short on availability of space, look into the 2004-2006 Jeep Wrangler Unlimited (lovingly referred to as the LJ or TJU), as they are exactly the same style but with about 12” more length in the tub and frame.
This comment makes me smile so much!! THANK YOU! It made my day the first time I read it and now that I answer it! Yes, we are super excited to collaborate with Off road performance in Waukesha - they are eager to learn about conversions and all "the electric stuff" and we are happy to have somebody in the project who knows what they are doing from a Jeep perspective - great synergy - let's see where it takes us. Great suggestion also with the Unlimited, then we can make one with even more range. In any case, that's not the last Jeep that we will convert.
Really Awesome all the reports you are doing. It´s really nice all the comments and the ways you work. Many thanks for sharing
Regards and waiting for the next video.
Thank you so much! I LOVE reading those comments - we are having so much fun and aI am glad that you enjoy our content!
Great content guys! Awesome progress!
Thank you!!!
I really like your project. I will try to follow your way to build my own electrified jeep in the future.
Wohoo, let us know how it goes!
Excellent video!
Thank you! 😊😊🙌🙌🔋
If you're worried about the battery modules underneath with the driveshaft running in between. Why not just ad a driveshaft safety loop secured by the pack's themselves? That way if the shaft breaks it'll be at least somewhat contained. 🤔
Fascinating stuff here. I really liked how you shared the 3d modelling&scans. Shows a lot of what goes into a project like this.
I can't wait to see what the final configuration looks like. 👍🏻
Love the information and the detail.
Thank you! I am really glad to hear that!
This series is amazing! Thanks for putting in all the work to share it.
Thank you! ☺️
I know I am late and this project is done. But in the future please use class 0 gloves rated for 1k Volts or more, with leather protection when you are messing or modifying HV systems. I also recommend sockets a, extnosion, and other tools that are insulated when you can. I do not want to hear or see anyone of you get hurt. Other than that I am loving this. I do diagnostics, programming and other computer stuff in automotive. I have recently started doing hybrids/ev vehicles as part of the business. I am also a pretty big nerd for this stuff so I love watching this stuff.
Thanks for the comments and concerns about safety and you are right...when dealing with high voltage, the proper PPE (Personal Protection Equipment) is needed. We do have HV gloves and insulated tools for use when the battery and system is in it's high voltage state. While the modules alone are still containing a high amount of energy, they are not high voltage (less than 70VDC).
@@ElectrifiedVeronika yes you are right anything 70 volts or less you don't need it the protection. Excited for the next projects
Don`t forget each cell is going to have its max and nominal charge and discharge way to find the optimal discharge is fully charge the cell and put in under a load for the voltage to drop to be no more than 10 to 15% (4.2 volts down to 3.6 or 3.5 volts). This manner will insure the cell never gets over worked and will last alot longer from not heat stressing from discharge. Ive often found factory specs to be a bit over the ideal rating. Once you find the optimal current drain you can build your battery to be a closer match to your motor controller. Voltage loss = speed loss and also creates heat. Im a firm believer in not wanting to see my batteries go over 50c to 60c under a load.
Hello hello.nice to see your good jobs
Thank YOU! So glad you are enjoying the content! ☺️
Cell testing sounds complicated and annoying. I wish you success!
Once you know what to do, it should be kind of fun. At least for us it is hehe. But figuring out the right test system for cells and modules and the right automation system was a challenge - but we think we finally found something nice and something that other crazy people could replicate. Thank you!
Good vid, looking forward to see how you set the batteries up to get to 400. Do you know what vehicle these modules came out of? They look like some I've seen from a Hyundai but there are so many that is just a guess. The ability to modify them really helps make them fit another car. Also, how do I find pricing on the Cascadia motors and inverters? I see a beginning price on Stealth EV for one model but nothing else. I didn't know if you can buy these direct or through a dealer?
Good job guys.
They are from a crashed Mustang Mach-E... As for Cascadia prices...I think Legacy EV is a good start.. legacyev.com/products/cascadia-motion-im-225-kit
@@donaldwright7194 Thanks
Thanks guys lot of info!! And I like to know do you using DIY chademo?
Thanks. I have a deep interest and desire to convert a car to an EV. But have no idea what to do. I know it’s not just plug and drive components but I do not have an electric or mechanical background.
It is a huuuuge undertaking! Hope this playlist helps you a bit to get an idea of what it involves. We get help from a fabricator for the welding and fabrication parts - could have never done that alone. If you have (a lot of) time and dedication and a couple people around you to help, it's a really cool thing to do with lots of learnings!
Not sure if you can explain the reason you chose that motor. You kinda explained that you want to reach 100mph at 4400rpm but: what RPM range you want to be in? can you use the whole range of the motor RPM or you want to stay between a range to be more efficient, or to have enough power for example at low speeds?
So in our case, we wanted to use that motor with the incorporated 3:1 gearbox which makes the motor RPM of 0-12000 RPM down to 0-4000 RPM and gives us power and torque we wanted for our application. So, yes, we will be using the full range of the motor utilizing the gearbox.
@@ElectrifiedVeronika Thank you for explanation.
Hi! Great video. What software do you use for fluid mechanics and thermal management simulations? Thanks!
Right now we are using Cradle for CFD analysis and thermal management. More to come soon! Let me know if you have specific questions.
Good info. The only issue is that nobody does a conversion for a useful car like a VAN or RV. I would be curious to see what kind on motor and components are needed for a Van or RV. If you fill out a VAN roof or RV roof with solar power you can add few KW of power in the batteries every day. on a small 33ft RV you can add at least 4-5 kW of solar. in a sunny day that can give you up to 30KW of extra energy; and solar panels become more efficient every year.
Most everything that we are doing for the Jeep would be perfectly suited for a VAN or Bus, especially the electric motor. The conversion would be even easier in a sense that you have way more space for batteries and hence more range 😊 A school bus would be on my todo, but also an old VW bus would be really cool. 😊
@@ElectrifiedVeronika Correct, the reason I like your series.
I want to convert a 2015 Land Rover Discovery (LR4). This will be a very long term project obviously. A lot of this information is very very useful and transferable. Thank you. The big questions I have regard interfacing the new EV drive train with the rest of the car’s communication busses. Simulating signals the ECU doesn’t seem as if it would be the best way, but how about simulating the signals the ECU would be outputting? And conversely responding to what the Ecu receives from other modules? For example if I put the ev motor to the transmission, could I get the various drive modes to still operate, or would it be best trying to reverse engineer what the drive modes (terrain response) are doing. Sorry. So many questions. And I’m probably starting from the middle even think these things.
Hi Peter, could you give me an update on how far you have got.
I’ve been thinking of this recently.
Plenty of 90 and series vehicle being converted. They have minimal networks involved in them.
I don’t know if LR4 has flex ray or just CAN, would have to look it up. RAVE or workshop manuals for this.
You can sniff the CAN but would need more complex hardware to do Flexray - Canalyser and the right box to input and output.
Canalyser can do this and have been with engineers doing it on later vehicles.
It all depends on how integrated they are
You need to output back on the network the messages it is expecting.
Take care M.
I have a 1987 Jeep Comanche I am going to convert to electric. How do you feel about using a pickup truck bed toolbox (modified to be waterproof of course) for battery containment/ placement? My only real concern would be making it too top heavy since it already has a 4.5" lift. I love the channel guys, keep working your analytical and logical magic.
I'm converting an 85 Cherokee Chief. have you chosen the components for your drivetrain?
Hi, would have thought “inserting the battery above the chassis would be the best answer if you have the lift.
The COG need to be kept low and within the wheelbase.
Motors are small, using Tesla motors would be one way and running independent suspension.
Lots of possibilities.
Take care M.
When it comes to heat dissipation, are you planning on integrating the cabin heating with the heat from the battery? Or would that be a different temp feature (like adding AC as well)?
We will not do AC, we just take the top off, hehe. The same heater heating the battery will be heating the cabin but there will be separate loops. More on that in future videos!
I need do this with my car who you hire or website to buy the parts.
We will have an info event pretty soon, stay tuned and sign up for that one to get started! Thanks for your interest.