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Trev

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Joined: 15/07/2006
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Posted: 08:05pm 14 Apr 2014
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electrondady1
Send me an email DrivebyNature@gmail.com and I will send you Relativities information pages.

Trev @ http://www.thebackshed.com/basiclynatural/
 
Trev

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Posted: 12:15am 11 Aug 2014
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I think maybe it was a little quick to post that the Relativities double layer was working as it should. Some time later it showed up as the two ends of the series string went high. A few theories were banded around. Some other tests were carried out, but no answers why this happened. A strange phenomenon. Not explainable, well at least not yet.

Here is a graph of the end of charge (peak pack voltage). The voltage of each cell is up the left hand side. Lowest cell reading 3.45v and the highest cell reading 3.71v. The bars at the bottom indicate where the Relativities were, which cells they covered.



For a good while now, I have been running 14.8v chargers (across 4 cells) and a single layer of Relativities. The Relativities are not overlapped. The 14.8v chargers are driven from 240vac switched by a relay when the Zivan NG3 finishes (at 182v) and takes the pack to 192v. The cell voltage difference every morning after charge is usually around the same, lowest 3.63v and highest 3.72v. Picture taken this morning, charged last night after being at another car show yesterday. (this car is in lots of shows, I don't write about them all)



We are also just past the 1 year mark for the WB LYP 260ah lithium pack. This pack was fitted with speedo reading of 437956. the speedo reading now is 462303. So far has traveled 24347km. No sign of any problems yet.


Edited by Trev 2014-08-12
Trev @ http://www.thebackshed.com/basiclynatural/
 
Downwind

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Posted: 04:54am 11 Aug 2014
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editedEdited by Downwind 2014-08-21
Sometimes it just works
 
Trev

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Joined: 15/07/2006
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Posted: 12:58am 15 Jul 2015
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It is now 2 years driving on the 260Ah pack.
For the past year speedo reading 462303 to 481132 = 18829km
Total for the 2 years is 437956 to 481132 = 43176km
They are still performing well.



Trev @ http://www.thebackshed.com/basiclynatural/
 
Trev

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Joined: 15/07/2006
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Posts: 454
Posted: 12:11am 22 Jun 2016
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The third set of new brushes is now fitted to the WarP 11 motor.

The second set of brushes started at speedo reading 444158. The speedo reading now is 503815. That's 59,657km for the second set of brushes. Very close to the first set of brushes that lasted 59,288km.

A new VDO satelite speedo fitted a while ago. It now has a reading of 17227.4km.





Edited by Trev 2016-06-23
Trev @ http://www.thebackshed.com/basiclynatural/
 
Gizmo

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Posted: 02:03am 22 Jun 2016
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How much does a set of brushes cost Trev?
"Treat the earth well, it was not given to you by your parents, it was lent to you by your children"

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Trev

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Posted: 01:38pm 06 Aug 2016
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Cost of brushes, don't know.

We are just passed 3 years on the second set of lithium batteries (52 cells x 260Ah). The speedo reading from last year 481132km to now at 506725 = 25,593km for the past year. Speedo reading when batteries were fitted 437956 to now 506725 = 68,769km over 3 years.

Pictures of original speedo and VDO speedo 20155.4km.



No issues with this battery pack. Just last week I had no auto balancing system installed and the pack stays in balance still quite good over a few days of testing.
No sign of capacity loss but I am not discharging very low to find out either.

I have had the new concept Relativities prototype auto balancers across this pack for a good while. They do work well but will most likely not be made commercial.



A few weeks ago I had been testing a new auto balancing system but something seems to be wrong that I have not been able to work out yet. I have them all removed until I have more time to test them more. Preliminary testing on my camper battery seems ok, but something is not right in the Hilux.


Edited by Trev 2016-08-08
Trev @ http://www.thebackshed.com/basiclynatural/
 
Trev

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Posts: 454
Posted: 02:42pm 06 Aug 2016
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Another feature for the EV Hilux, sometime ago, I put in more solar. Separate systems to charge the EV Hilux direct. The 52 cells are divided up in 3 banks of 16 cells for 48v charging and 4 cells on the end is charged as 12v.

The 4 regulators are programmed to be exact 3.5v per cell over the entire pack. Changeover switches make it easy to switch between the house battery bank (48v) and the EV Hilux battery banks.

Charging direct from solar is much quicker with the solar than 2 x Zivan NG3 chargers. The NG3 chargers together can charge at 32A. The 3 x 48v systems are max at 80A on a good day. The 12v system needs more solar panels to match the 48v systems, but the regulator is an older PL60 I had here and is only 60A max. The 48v systems are the new PL80 regulators.








Trev @ http://www.thebackshed.com/basiclynatural/
 
Trev

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Posted: 01:34pm 02 Oct 2017
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We are passed the 4 year date for the second lithium battery pack - 52 cells x 260Ah. The first drive was around the 15 July 2013 with old speedo reading of 437956km.
Old speedo reading now is 527178. So 527178 - 437956 = 89222km traveled to date.

If we use the new VDO speedo, my calculations make it.......
- old speedo 503815km when the new VDO was recorded at 17227km (taken from an old posting) would make the new VDO fitted 0km, with the old speed at 486588km.
- old speedo distance 486588km - batteries fitted at 437956km = 48632km
- New VDO is now at 40712km + 48632km = 89344km traveled to date.

Edit: old LFP pack did 87803km. Current LYP pack is almost the same distance already.

Batteries are still going well. We did lose one cell (developed an internal short and went to zero volts with some smoke - no fire) which has been replaced. The new LYP chemistry are much better than the old LFP chemistry (first battery pack was LFP chemistry). It was at the 4 year mark with the LFP batteries losing enough capacity that I added the extra 8 cells to boost the range back to where I needed it. Admittedly, yes, this current LYP battery pack is bigger from new, but it is not losing capacity like the old LFP pack did. Some of the new LYP cells show more voltage sag now than when they were new but capacity still appears to be good. A couple of cells have developed a slightly higher self discharge than the others so balancing is more important now. Overall, this LYP battery pack is going very well still. I can still pull 1000A on acceleration - gives the V8's a surprise.



A side note, the old LFP battery pack (from Hilux to house solar) is still going on the house. Last I checked (earlier this year) was still holding around 50% capacity. Solar is very soft on them.
Edited by Trev 2017-10-03
Trev @ http://www.thebackshed.com/basiclynatural/
 
Warpspeed
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Joined: 09/08/2007
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Posts: 2915
Posted: 02:42pm 03 Oct 2017
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Great thread Trev.

I have had much the same experience with my thirty 50Ah Winstons. The voltages are almost identical if the battery is left to settle over a day or so, but during charging the voltages really spread, but come back to almost equal when the battery rests after charging.

Its just a matter of top balance. I am not sure that the charge shuffling "smart" balancers would have enough grunt to be effective with really large cells, except over a very long period.

It seems that the only time top balancing will be really effective is while the voltages are actually spread, and that only happens during the final stages of actual charging. As soon as charging stops or a few hours after, there is not enough difference there to balance. Once the cell voltages relax and go back to being almost even, there is not much difference for a charge shuffling system to work with.

Currently building some voltage sensitive discharge loads to bolt onto each cell.
The voltage threshold matching seems to be extremely critical, but its possible to divert a much larger current that way than with very slow charge shuffling method.

All interesting stuff.




Edited by Warpspeed 2017-10-05
Cheers, Tony.
 
Boppa
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Joined: 08/11/2016
Location: Australia
Posts: 807
Posted: 12:35pm 04 Oct 2017
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"gives the V8's a surprise. "
Just as a matter of interest, how fast is the acceleration?
(like 0-100)?
I have the 2.8 (non turbo) and it sure aint no v8 killer LOL

I timed mine and got a blistering 22 sec 0-100- actually slower than a mates vw kombi which was faster at 19 sec.

:-(

Beaten by a kombi....
(admittedly I can put 3.5t on it and it still seems to take about the same time-go figure)
 
Gizmo

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Posted: 07:16pm 04 Oct 2017
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Is that kmh or mph?
"Treat the earth well, it was not given to you by your parents, it was lent to you by your children"

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Boppa
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Joined: 08/11/2016
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Posts: 807
Posted: 08:04pm 04 Oct 2017
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kmh

0-100mph estimated time not until after the heat death of the universe.....
(or it falls off a very tall cliff)

had it to 125 once, that took several minutes...

She'll pull the earth around, but fast she is not....
 
Trev

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Joined: 15/07/2006
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Posts: 454
Posted: 01:58am 05 Oct 2017
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I have some performance data here http://www.thebackshed.com/basiclynatural/EVConversion.asp
0-100km/hr starting in third gear, changing to 4 gear in 12 seconds. In first and second gear it jumps quite well.

Yes the EV Hilux can take the loads too. I can take 1000kg on the ute and another 1000kg on the car trailer. The biggest lithium battery order so far is 6000kg, that's 3 trips to pick it all up. Here are some load examples.

Lithium batteries. We are doing this very regularly.


6 pallets of structural foam and fibreglass. Solar panels.


Electric outboard boat motor, importing from Golden Motor. Electric zero turn mower, built from scratch.


Solar hot water system. Solar racking.


EV Hilux and T-Rev, electric trike, built from scratch. I will do a separate thread on T-Rev some time later. T-Rev was in 3 car shows in the last few months. The EV Hilux towed T-Rev on the car trailer to the shows (you can see the trailer in the background of car show pic). T-rev is almost finished, should have it registered soon. Please don't carry this on in this thread. This is an EV Hilux thread and this posting is on loads and performance.


Trev @ http://www.thebackshed.com/basiclynatural/
 
galderdi
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Joined: 12/08/2016
Location: Australia
Posts: 66
Posted: 06:53am 06 Apr 2018
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Nice work Trev.

 
Trev

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Joined: 15/07/2006
Location: Australia
Posts: 454
Posted: 10:42am 22 Aug 2018
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Another year has passed since fitting the 52 cells x 260Ah battery pack.
Last posting was - New VDO is now at 40712km + 48632km = 89344km traveled to date.

VDO speedo reading now is 64137 - 40712 = 23425km for the past year + 89344km = 112769km in total over 5 years.

I am not sure of the old speedo reading accuracy. The needle does not show speed anymore. The numbers still go around and I think its still reading ok. The old speedo reading is 550451km.



The battery pack is still holding up ok. There are some cells that have a higher internal resistance now, showing a voltage sag when under heavy current draw.

We have done a number of long drives now. I figure we have lost some capacity, but I have discharged 30kW from the pack, and possibly still has some more. I just don't want to damage the pack by discharging too low. It is still at least or over 150km range.

Two examples I have taken some pictures. Driving conditions, wind, terrain etc do make a difference to what you can achieve.

135km using 23.1kW. Don't take any notice of the temperature in the monitor screen. It is not that hot.



139km using 27.7kW


Edited by Trev 2018-08-23
Trev @ http://www.thebackshed.com/basiclynatural/
 
Trev

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Joined: 15/07/2006
Location: Australia
Posts: 454
Posted: 12:22am 05 Mar 2019
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The third set of brushes is done. Forth set now fitted.
Old speedo reading now, 563143, minus speedo reading when fitted 503815 = 59328km
VDO speedo reading now, 76925, minus speedo reading when fitted 17227 = 59698km

All 3 sets of brushes have lasted just over 59,000km.



Re:-

Glenn, new brushes AUD$460. I dislike very much the USD/AUD exchange rate, it makes the Aussie dollar not worth much. It makes our prices so high, because I have to pay more.Edited by Trev 2019-03-06
Trev @ http://www.thebackshed.com/basiclynatural/
 
galderdi
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Joined: 12/08/2016
Location: Australia
Posts: 66
Posted: 06:41am 10 Jun 2019
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Hey Trev, It will probably be a while until you need brushes again but when you do you might like to try a mob at Narangba called Cortela Carbon. I purchased some spares from them for my car. I am not suggesting they are cheap. But considering the freight costs and exchange rates it is worth exploring them as another option.
 
Trev

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Joined: 15/07/2006
Location: Australia
Posts: 454
Posted: 01:57am 02 Sep 2019
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There is quite a bit of news worthy of posting, so I will attempt to play catch up in the next few posts.

We are now passed 6 years for this lithium pack.
VDO speedo reading is now 88599km - 64137km = 24462km for the past year + 112769km = 137231km in total over 6 years.
Old speedo is still turning around, the reading is 574725km - 437956km = 136769km recorded over the past 6 years.



November last year 2018, we won the Glen George trophy for the longest EV drive to the AEVA show.



This AEVA conference & show was held in the Brisbane Convention Centre. I only presented T-Rev for show as the space was limited and the costs were high. A long day. Bump in (setup) started at 7am. Visitors started at 10am and went right up to 7pm. There were a lot (a real lot) of visitors. Security were assisting in getting them all out at the end so we could pack up and get out. It was a great show day. We got out by 8pm.



Here is a snapshot of the charge points on the journey. One camping spot was Childers. Childers charge point is in the back of the RV motorhome/caravan free camping spot. A great location.









Then all the same charge points in reverse on the way home. Different charge points in the dark. Carmilla, the last public charge before getting home was in the light. You can find all the charge points at  https://www.plugshare.com/


Edited 2019-09-02 12:06 by Trev
Trev @ http://www.thebackshed.com/basiclynatural/
 
Trev

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Posts: 454
Posted: 11:49pm 02 Sep 2019
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We have done a lot of traveling away for EV shows. Last year, 2018, we showed at the National Transport Museum EV show in May, then Noosa a week later.

Here is the map with all the charge points marked. The map shows 3252km in total. We recorded 3374km from our VDO speedo.



In Toowoomba on the way down we tried out a Tesla charge point. It works!



National Transport Museum EV show in Inverell





East of Inverell there is a big wind farm. We were not allowed in, so just took some photos from a distance.



Noosa EV Expo
Mark Bailey Qld Transport Minister and Sandy Bolton MP Independant Member for Noosa drop by our show. Always nice to see happy politicians. It was great to meet these lovely people and have a chat.



Check out the pictures and videos in these links.

https://www.facebook.com/WINNewsSunshineCoast/videos/1973580156008751/
https://drive.google.com/drive/u/2/folders/1hAI6hsBXmkHIGyqQGOFGYoB6kuHZ5RFS
https://drive.google.com/drive/u/0/folders/14Ub-W6-kgWDlnKtUSncwz8_iLsZaozuH
https://noosatoday.com.au/stories/16-05-2018/built-in-the-back-shed/
.
Edited 2019-09-03 10:59 by Trev
Trev @ http://www.thebackshed.com/basiclynatural/
 
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