Ford Ford Ranger EV Component ListRanger EV Component List
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Transcript of Ford Ford Ranger EV Component ListRanger EV Component List
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EV CONVERSIONMAYOR COMPONENTS
AND PARTSJomel Maldonado
Adrin Bagu
Jos M. Cruz
Advisors
Awilda Melndez
Edgardo Desardn
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Donor vehicle
The proposed donor vehicle is a 2010 Ford Ranger orsimilar, with an approximate curb weight of 3120 pounds
before the conversion. A rough estimate of 500 poundswill be reduced once the internal combustion engine,radiator, fuel system, fuel tank, exhaust system andassociated parts will be removed for the conversion. Theautomatic transmission should be changed to a manualtransmission to reduce dissipation of power from theelectric motor and increase the range of miles betweencharges. The manual transmission will have the originalclutch and all 5 speeds available.
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Donor vehicle
The supplemental restraint system, air bags and AntilockBraking System will remain functional to comply with NHTSA,
DOT and other regulatory agencies. All other functions likeWipers, Horn, Seat Belts, Lights and Signals will remainoperable to comply with the DOT agency and to be certified asa road worthy vehicle. The CAN Bus communication will remainoperable, thus the instrument cluster will remain functional.Power steering and power brakes will remain as effective asthe original vehicle configuration. The total weight after theconversion is estimated to be 3800 pounds. The estimatedrange between each charge is 45 miles if driven at aconservative 40 MPH. The estimated energy consumption is385-500 watts-hour/mile.
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Manual Transmission
Since the automatic transmission dissipates a lot ofenergy in the form of friction, heat loss, rotational inertiaand viscous coupling, it will be replaced with a 5 speedmanual transmission for better drive train efficiency. Thereplaced transmission should be from a Ford Ranger witha 4 cylinder, 2.3 liter engine since it has optimal gearratios for the electric motor.
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Electric Motor
Warp 9 inch series wound DC motor, double ended shaft
Continuous Ratting = 28.8 HP / 70 lb-ft @ 72V/334.5A
Peak Ratting = 70 HP / 143 lb-ft @ 120V/435A
Max. Efficiency = 89.1
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Electric Motor
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Electric Motor
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Adapter Plate
An adapter plat will be used to couple the Warp 9 electricmotor to the manual transmission; it will retain use of theoriginal clutch. A customized aluminum coupler will matethe electric motors shaft to the manual transmission
clutch. In order to achieve reverse operation of the drivetrain, the mechanical gears will be used, thus eliminatingthe need of typical H-Bridge electrical configuration; thiswill simplify the circuit and reduce voltage drop.
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Controller
Warp P Drive controller with Pulse Width Modulation capable ofmanaging up to 1000 Amps of current at 170 volts maximuminput voltage. The approximate weight is 16 pounds.
Additional options that can be upgraded:
Cruise Control
Tachometer Input
Battery Management
Digital display output via CAN Bus communication
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Pedal Sensor
Used with the WarP-Drive Controller, Dual Hall Effect
sensors are used, to produce a signal that does notdeteriorate over time and use.
Based on the Toyota Prius Pedal sensor.
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Interface Module
Digital display connected with the controller output via CANBus communication for the following parameters:
1) Motor Amps and Volts , Battery Amps and Volts
2) Controller Temperature, Throttle Position
3) Error and warning codes
All internal sensors and displayed parameters can be saved fordata logging in a Mini SD Card.
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Traction Battery
A total of 45 Thunder Sky LiFeYPO4 Batteries will beconnected in series; each battery produces 3.2 volts andhas an amp hour capacity of 200 amps at a 20 hour
discharge rate. The total voltage will be 144 volts with anavailable power of 28.8 kW. Each battery weights 16.10pounds, which will increase the vehicles weight to anadditional 724 pounds.
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Charger
To recharge the traction batteries, a solid state 3 kW highfrequency charger will be employed. This charger has an
input of 120-230 VAC and a programmed output of 24-144VDC @ 16-80A The power factor is at 98%.
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DC-DC Converter
A solid state DC-DC converter will charge the auxiliarybattery (12 volts) with the traction batteries (144 volts). It
has an input of 100-200 VDC and an output of 14VDC @60 amps.
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Power Brake
An electric vacuum pump with a reservoir will substitutethe original vacuum source that was obtained from the
internal combustion engine. This will assure the safeoperation of the power brake system.
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Power Steering
An electric motor will drive a mechanical pump to keep
the original power steering assist of the vehicle.
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J1772 Charging Connectors
The J1772 Adapter box is used to connect a J1772
Charging Station, EVSE, to a NEMA receptacle. TheAdapter Box contains a pilot signal generator that enablesthe 220 Volts AC in the EVSE.
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Estimated Budget
Description Amount*
Components and Materials $17,200.00A or $25,800.00B
Student Wages $6,000.00
Faculty Wages $4,000.00
* Estimated amountsA Flooded Lead Acid BatteriesB Lithium-Ion Batteries
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Questions