Electric Vehicles: May 2011 Archives

Piaggio Boxer EV v4: Revised BOM

By
Karen Nakamura
on May 9, 2011 2:03 PM | | Comments (0) | TrackBacks (0)

I burnt out the original brushless motor and installed a new one, here's the new revised bill of materials (BOM) (dated 2011.5):

PiaggioBoxerEV4
Base Unit Piaggio Boxer (1971)
- 50 cc 2-stroke internal combustion engine (removed)
Electric Motor Turnigy 80-100-A 180Kv Brushless Outrunner from Hobby King
  • - Tachs: 7700 rpm @ 43.2v nominal (6500 rpm @ 36v)
  • - Max amps drawn: 140A @ 43V
  • - Max watts drawn: ~ 6 kilowatts
  • - Geared with 250A front pulley and notched V-belt
  • - Speed: 50 kph top speed (at current gearing)
Electronic Speed Controller Castle Creations Phoenix HV-110 (link)
- 110 amps @ 50 volts limit
- Force air cooled
Throttle Magura 0-5K Potentiometer motorcycle twist grip throttle
Servo Tester (Pot to ESC) Boman Industries Polar-Matic PC-50 (ebay)
-modified for use with Magura pot and HV-110
Power Monitor Cycle Analyst (link)
Batteries Prius Gen 2 NiMH
- 6S2P packs (12 in total)
- 43.2 volts nominal @ 6.5 Ah each
- 43.2 volts nominal @ 13 Ah combined
- 330 watt-hours (conservative)
- Range: unknown but estimated 7 km based on 45 Wh/km and 330 watt-h calculation
Power Connectors - Anderson PowerPole 75A on main connections - link
- Anderson PowerPole 30A on sub connections - link
Wiring - 8 gauge stranded copper on main power lines and motor leads
- 12 gauge stranded copper on sub power lines
Lighting - Front lighting using 10-Watt LED (driven at 12v @ 750ma; specced at 500~600 lumens @ 6500K )
- Rear lighting using high-power red LEDs
Low Voltage (48VDC to 12/5 VDC) DC:DC Converters
  1. Twin 12VDC @ 3A DC:DC converters using the National Semiconductor LM2576HVT-12-ND buck-converter
    1. Unit 1: Front and rear lighting, motor cooling fan
    2. Unit 2: ESC controller cooling
  2. 12 volt to 5VDC converter using MC34063 Based Switching Regulator for front lighting (currently bypassed)
  3. Quark Pro BEC 3A 5V UBEC for servo tester / RC components
Things I burned out/destroyed
  • E-Sky EK2-0907 Servo Tester
  • Doc Wattson power monitor
  • ELF 100 ESC speed controller
  • Castle Creations Phoenix HV-110
  • HXT 80-100-B 130Kv Brushless Outrunner motor
  • Right index finger on burnt out ESC
  • Power diodes for battery tap
  • Various burns and scrapes
  • My pride :-)

Please leave comments and questions on this post!

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