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Hybrid vehicle generation controller


By bkrahmer, Section Homebrewed Electricity
Posted on Tue Mar 16, 2004 at 10:13:04 PM MST
Please help me build my VoltsWabbit

I've been playing around with the idea of building a hybrid electric vehicle.  I want to take a VW Rabbit, put an electric motor in it, a 72V battery bank (6x), and a power generation system.  The latter is what I need help with.  BTW, I'm a software engineer and tend to come up with complicated solutions, and haven't played with electronics since I was 13.)  Ideally, I want a black-box system which does the following...  
  1. When the battery bank voltage drops to a certain point, the 'generator' is started.
  2. a. The 'generator' will be a small gas or diesel engine running a DC generator.
  3. b. The generator will have a dumb electric start system, so when it needs to be started, 12V (from an aux battery) needs to go to the starter for a fixed time period (2 or 3 seconds maybe.)
  4. c. After the engine has reached its running RPM, the DC generator needs to be connected to it's load (the battery bank.)
  5. When the battery bank voltage reaches a certain point, the generator needs to be shut down.
  6. a. First, the load must be disconnected.
  7. b. Second, the engine must be shut down.  Let's assume a gas engine, because it's simple to shut down a small gas engine.  We can short the coil to ground for approximately five seconds.
So, if I haven't forgotten anything, we end up with a pretty small loop of fairly simple tasks.  The problem is that I have no idea if this can be done with simple electronic components, or where to start.  I also need to come up with a charging method, to convert my 30V DC to 72-86V DC to charge the battery bank.  The PWM charger as documented by Virgis looks very interesting, as does the DC-to-DC capacitive charge transfer system as documented by charged.  I'm going for efficiency.  BTW, the generator is spec'd at 9000W.  

I would appreciate any input you can give me.  Thanks.  
brian

Hybrid vehicle generation controller | 8 comments (8 topical)

Re: Hybrid vehicle generation controller (none / 0) (#1)
by drdongle on Wed Mar 17, 2004 at 05:23:35 AM MST

 I would suggest searching Yahoogroups for an EV group who would be better equiped to help you.

Dr.D
Carpe Vigor, Dr.D



Re: Hybrid vehicle generation controller (none / 0) (#2)
by bkrahmer on Wed Mar 17, 2004 at 11:02:10 AM MST

I will keep looking for more appropriate places to find the info I need.  However, I don't hold much hope for EV groups.  First of all, building an EV is not the same as building an HEV.  I can build a complete EV with one order from evparts.com.  Building an HEV is quite a different story.  

I'm hoping that I will get some more (better) answers.  :)  I'm reviewing information on op-amps and refreshing my memory on logic circuits to see if I can put something together myself, but I sure would appreciate some help.

thanks,
brian

[ Parent ]



Re: Hybrid vehicle generation controller (none / 0) (#3)
by TomW on Wed Mar 17, 2004 at 11:29:15 AM MST

bkrahmer;

Hmm software engineer. Why not solve the control issues in software that utilizes the parallel and serial ports to sense and control?  Once you have the flow chart figured out you should be home free doing the control and sensing end.

Just the first thoughts.

Sensing and sending a control value to a computer is fairly simple and well documented as is driving high power circuits from a printer port. I do both via perl and crond with a digital rs232 meter.

My advice is to break it down into pieces and solve them as individuals.

I seriously doubt a "black box" is gonna turn up.

I have lots of ideas on the computer control side using cheap low end laptops but I am not up to typing it all out today.

Cheers.

TomW

The Truth is the Truth, even if no one believes it; and a lie is a lie even if everyone believes it




Re: Hybrid vehicle generation controller (none / 0) (#5)
by bkrahmer on Wed Mar 17, 2004 at 12:44:29 PM MST

> My advice is to break it down into pieces and solve them as individuals.

Very good advice.

> I seriously doubt a "black box" is gonna turn up.

What I meant by 'black box' is that the generation is automated.  I don't want to bother with manually controlling the generator with a bank of switches, etc.

> Why not solve the control issues in software?

I think it would take me just as long to figure out how to hook up my parts, customize an OS that would boot off CD so I don't have to worry about power-down issues, etc, etc.  It still wouldn't get me to the heart of the problem, which is the solid-state components that I don't know so well.

After breaking down the problem further, I'm having some clarity.  Here's what I've got now (P1-P3 are voltage settings):

  1. When the battery bank voltage is below P1, the starting circuit is energized.
  2. The starting circuit consists of an automatic turn-off relay connected to the engine starter.
  3. When the battery bank voltage is above P2, the starting circuit is de-energized.
  4. I can run a tachometer on the engine.  As long as the RPM is above X, a relay is energized which connects the generator to the battery bank.
  5. When the battery bank voltage is above P3, the shutdown circuit is energized.
  6. The shutdown circuit is a relay which grounds the coil to ground while power is applied.
Now my problems are reduced.
  1. How to create the circuit for #1 above?
  2. http://www.uoguelph.ca/~antoon/circ/relay62.html solved this.
  3. Should be a reversed version of #1
  4. Assuming I have an analog (volt-based) tach signal, should be the same as #1.  Otherwise?
  5. Again, same as #1.
  6. Same as #2.
  7. How to create the DC-DC converter.  BTW, I think I'm going with 10-12kw generator / 84V battery bank now.
The answer to #1 will obviously take me very far.  In fact, with that answered, I can build a miniature prototype to test my system.

thanks,
brian

[ Parent ]



Re: Hybrid vehicle generation controller (none / 0) (#4)
by ibedonc on Wed Mar 17, 2004 at 12:12:38 PM MST

I Plan on doing this also , I am going the Diesel route, then I can run the Diesel on
WVO or biodiesel



Re: Hybrid vehicle generation controller (none / 0) (#6)
by richard on Wed Mar 17, 2004 at 06:15:14 PM MST

  HomePwer issue 97  Page 97 ..Homemade hybrid.. good luck richard c



Re: Hybrid vehicle generation controller (none / 0) (#7)
by veewee77 on Wed Mar 17, 2004 at 09:19:30 PM MST

I would do the engine control with software and use a Parallax BASIC Stamp microcontroller.

They are easy to use and the software is very easy to use.

the "black Box" you are talking about could be possible that way.

DS



Re: Hybrid vehicle generation controller (none / 0) (#8)
by veewee77 on Sat May 01, 2004 at 08:49:37 PM MST

http://electroauto.com  will give you all the parts and info you need.

Doug




Hybrid vehicle generation controller | 8 comments (8 topical)
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