Michael Hackleman Published by

215 Pages·020.45 MB·English

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first in a series by
9
kooB Design and Production by Vanessa Naumann I
Another Ea &mind/Peace Press Publication
Copyright@1977 by Earthmind
All rights reserved
1st printing -- April 1977
Library of Congress Catalogue Card
Number:
ISBN: O-915238-17-9
Hackleman, Michael A
Electric Vehicles .
“Another Earthmind/Peace Press publication D”
Bibliography: p .
1. Electric vehicles--Design and construction.
T. Title.
TL220 .H3 629.22’93 77-6158
ISBN O-915238-17-9
Other books by Michael A. Hackleman
WIND AND WINDSPINNERS --- A Nuts and Bolts Approach to Wind/Electric Systems
and THE HOMEBUILT, WIND-GENERATED ELECTRICITY HANDBOOK
Additional single copies of these three
books may be obtained from:
EARTHMIND
5246 Boyer Rd.
Mariposa, California
95338
for $8 (includes bcok-rate postage and handling)
or $10 (foreign orders). California orders add
6% sales tax.
EARTHMIND is a non-profit corporation pursuing alternative energy
research in these and related areas. For more information about
us and our other publicctions, send a stamped, self-addresT.:!,
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a
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r
Designing and building an EV is akin to writing a book. Even this book. It’s
a process of integrating what you know and have, finding out what-you don’t
know, trying to put it all into a proper sequence. The order-of-importance
idea doesn’t work here, though. There is no part of an EV, or most anything
else, that’s not important. If it wasn’t part of the whole, it wouldn’t be
there. You might be killed in an automobile because of its poor design or
because a cotter-pin fell out of a steering knuckle.
So, it becomes a process of talking about things, describing their association
with other things, without having it all become too complicated to comprehend,
much less to make decisions from. The design changes as you go through the
process. This is not so much a matter of compromising, but of simply coming
to understand yourself and what you want or need, and what you know, and don’t
know.
You should understand that I am an advocate of smaller vehicles on the road ---
electric or not. When you boil down all the controversy about big vs. small
cars, you’re left with one nasty bit of residue: big cars are preferred be-
cause they give the driver a good chance of surviving a crash with a smaller
car. I don’t like that attitude. One, it automatically means that you’re
deciding against the other guy --- you don’t get creamed, but he sure does.
Second, it makes you careless; if you don’t worry about accidents, you c’rlve
ihat way. Me? I don’t wapt to cream anybody. And, admittedly, I dorl’t want
to get creamed. I want to avoid a collison, not prepare for onea I’ 11 trade
agility for mass anyday; I want to be difficult to hit. Sure, I’ve got to do
a lot of defensive driving but, then, what else should a driver be doing?
I think small is nice because it mean& ecomony, range, and less dead weight to
haul around. I don’t have money to flaunt, so it stays simple, fixable, and
easy to operate. I’m not trying to impress anyone with my vehicle; I’m not
itching to compete with, or look like, gas-guzzlers or space-hippie vans. I
don’t carry a circus around with me; at the most, I’ve got my ladyfriend. I
save acceleration and power for emergencies; I like to leave ‘ihe rubber on
my tires, not on the road. I’m not trying to break any EV land or air speed
records. I’m a high-energy person, and I don’t like to move slow, but safety
keeps telling me to slow down. So, I do my designing with that in mind.
Whatever you decide to do, I hope this book gets you a lot closer to it;
that was my intention in writing it and, looking back through all these
pages, that’s the way it feels. Good reading!
people
A few have made it very pleasant for me to write this book. Our typist,
who wishes to remain anonymous, deserves many thanks. There's Hendrik Rienks;
he hasn’t helped directly, but has done all of those things around the farm
that demand our much-divided attention, and it liberated our time to give this
book the energy it needed. I thank Megan Dehn for her efforts, proofreading
and catching hundreds of tinky typo, syntax, and nonsense errors; as well, she
has worked along with Hendrik, handling everything else. And rn the midst
of the turmoil there was the quiet gentleness of Will Evans, building, dig-
ging, planting, mending, and cheering us on; his month-long visit was all
too short.
Help came from afar, too. Again, one of my books is laced with cartoons from
Jim DeKorne of El Rito, New Mexico; these are always a nice surprise. And, of
course, Mark Dankoff couldn’t help but do some very butterfingery electronic
drawings, turning pumpkin sketches into royal schematics. Mary Leonard took a
few moments away from the gas pumps and other sundry chores to whisk out some
fine mechanical illustrations for Chapter 4. And, from Jim Dunn and the
other folks at Taylor-Dunn Manufacturing Company in Anaheim, California,
came permission to reprint drawings from several of their industrial electric
vehicle service manuals (notably Figures 2-11, 2-12, 2-20, 4-8, 4-17, 4-18 and
4-19). Most grateful!
And, the best saved for the last, I appreciate the work of Vanessa Naumann,
my ladyfriend and this book’s designer. Layout, proofreading, arrangement,
cover, cartoons, and photos, by critic, advisor, and friend --- all in a
little more than a hundred pounds of warm human being. The words seem some-
how inadequate.
I dedicate this book to Kuby. She might try to deny it, but she had a lot to
do with me being here in the first place, to write this book.

---FUNCTIONS
Design Process:
Type of EV
L&al vs. Distant Travel
The UTLEV and the PASEV
The B+irit~
Speed
Weight
Range
Power Capacity
Interrelationships
Source
The Ownerbuilt EV
qorized Bicycle
The Three-Wheeled UTLEV
EV Classes
--MECHANICAL POWER
Motor
AC vs. DC Motors
The Series Motor
The Shunt Motor
The Compound (Wound) Motor
The Permanent Maanet Motor
Determining Motor Horiepower 22
HP Formula for EVs
a. The Coefficient of Friction
b.. Vehicle Weight
c. The Constant ‘k’
d. Vehicle Speed
e. Divide by Horsepower
f. Hill Climbing
Motor Voltage and Current Ratings
Motor RPM
Other Motor Factors
a. Cooling Needs
b. Motor Weight
c. Motor Mate-up
d. Mountings
e. Bearings
f. Electrical Connections
cost
Gearbox 37
Ynctions
Inside the Gearbox
Gear Ratios
Hillclimbing Again
Finding Gear Ratios
Fixed-Gear vs. Gearbox’ed EV
a. Simple Single-wheel Drives
b. Jack-shaft, Single-wheel Drive
c. Shaft Torque
Transaxle 48
--ELECTRICAL POWER
Batteries 53
Ratings
a. Capacity
b. Rate of Discharge
C. Deep-cycle
d. Voltage
Battery Pack
Other Battery Parameters
a. Case Type
b. Case Size
C. Weight
d. Terminals
e. Connectors
Maintenance
a. Battery Water
b. Hydrometer Readings
c. Maintenance Schedule
The Battery Compartment
Control B&
-sic Control Requirements
a. Breakaway Current
b. Speed
C. Motor Reversing
d. Overcurrent
Control Techniques
a. On-or-Off
b. Resistance Control
C. Resistive Control of Armature Current
d. Resistive Control of Field Winding
e. Resistive Control of the Armature and Field Windings
f. Voltage-Tap Control
. Chopper Control
Evaluiting Control Techniques
Practical Control Circuits
a. A Simple On-or-Off Speed Control
b. A Slide-Switch Armature Current, Resistive Speed Control
(cont.)
C. A Solenoid-Switched, Armature Current, Resistive Speed
Control --- Type I
d. A Solenoid-Switched, Armature Current, Resistive Speed
Control --- Type II
e. A Field Current, Resistive Speed Control
f. A Voltage-Tap Control -- Type I
A Voltage-Tap Control -- Type II
R: A Series Motor Reversing Circuit
.
1. A Shunt Motor Reversing Control
j- A Compound-Wound Motor Reversing Control
Special Circuits
a. A Series Motor Overspeed Circuit
b. A Compound Motor Overspeed Circuit
c. A Dynamic Braking Circuit
d. Regenerative Braking
Monitor 99
Indicators
Gauges
Ammeter
Voltmeter
Speedometer
Odometer
Tachometer
Temperature Gauge
Instrumentation Power
106
-2
Wipers
Mirrors
Spare Tire
Turn Signals
Headlights
Reflectors
Vent Fan
Heater F,,w
Interior k&&Z
Battery Compartment Light
Char&a 113
Charging Requirements
Charging Sources
a. Utility Charging
b. Automobile Power
C. Standby Generator Power
d. Alternative Charging
Charging Stction
An EV Charger
.--FRAME WORKS
125
qgle=Wheel Steering
Twin-Wheel Steering