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CITATION

Leitman, Seth. Build Your Own Plug-In Hybrid Electric Vehicle. US: McGraw-Hill/TAB Electronics, 2009.

Build Your Own Plug-In Hybrid Electric Vehicle

Authors: Seth Leitman

Published:  June 2009

eISBN: 9780071614740 0071614745 | ISBN: 9780071614733
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  • Contents
  • Preface
  • Acknowledgments
  • 1 Why Plug-In Hybrid Electric Cars Can Happen Now!
  • What Is a Plug-In Hybrid Electric Vehicle?
  • Why Should You Convert Your Car to a Plug-In Hybrid Electric Vehicle?
  • Understanding the Plug-In Hybrid
  • Internal Combustion Engine
  • Hybrid Electric Vehicles
  • Electric Vehicles
  • What Is an Electric Vehicle?
  • Electric Motors
  • Batteries
  • Controllers
  • Convert That Hybrid!
  • Reduce Our Reliance on Oil and Clean the Environment at the Same Time!
  • July 2007 EPRI-NRDC Definitive Study: PHEVs Will Reduce Emissions if Broadly Adopted
  • California Air Resources Board/ZEV States Report
  • U.S. DOE Argonne National Lab
  • PHEVs Are Cheaper to Run and Maintain
  • 20 to 25 Cents per Gallon?!
  • Purchase Costs
  • The Bottom Line
  • Payback?
  • Safety First
  • You Can Do It!
  • 2 PHEVs Save the Environment and Energy
  • How Do PHEVs Save the Environment?
  • Save the Environment and Save Some Money Too!
  • Fuel-Efficient Vehicles
  • So Who’s to Blame?
  • Toxic Liquid and Solid Waste Pollution
  • Toxic Input Fluids Pollution
  • Waste Heat Caused by Inefficiency
  • Electric Utilities Love PHEVs
  • Chapter Summary
  • The Legacy of the Internal Combustion Engine Is Environmental Problems
  • A Proactive Solution
  • 3 History of Plug-In Hybrid Electric Vehicles
  • Early Hybrid and Electric Vehicles
  • Lohner-Porsche PHEV
  • The Introduction of Plug-In Hybrids
  • Electric and Hybrid Vehicle Research, Development, and Demonstration Act of 1976
  • Partnership for a New Generation of Vehicles
  • Who Really Killed the Electric Car?
  • September 11 and Our New Understanding of Electric Cars
  • Hybrid Electric Cars Come to the Market
  • Toyota Prius
  • Honda Insight
  • Honda Civic Hybrid
  • Ford Escape Hybrid
  • PHEVs Come to Market Thanks to Andy Frank (the Father of PHEVs)
  • Hybrid Center at the University of California–Davis
  • The California Cars Initiative (CalCars)
  • CalCars Demonstration Conversions
  • Plug In America
  • EPRI-DaimlerChrysler Plug-In Hybrid Development Program
  • CARB Support for PHEVs
  • Economic Stimulus for PHEVs
  • Conversion Companies
  • Hybrids Plus PHEV
  • A123Systems and Hymotion
  • The PHEVs Available or Soon to Come onto the Market
  • Toyota’s Plug-In Hybrids Jumping In from Japan (First)
  • GM and the Chevy Volt
  • Fisker Karma Plug-In Hybrid Sport Sedan
  • AFS Trinity’s “Extreme Hybrid”
  • Ford Motor Company and the Escape PHEV
  • Phoenix Motorcars
  • Conclusion: PHEVs Are Here Today!
  • Game Changers
  • 4 What Is the Best Plug-In Hybrid Electric Vehicle for You?
  • Plug-In Hybrid Electric Vehicle Purchase Decisions
  • Conversions Save You Money and Time
  • Buying Ready-to-Run
  • Buying a Ready-to-Run Converted Toyota Prius from an Independent Manufacturer
  • Conversions of Production Hybrids
  • Converting Existing Hybrid Electric Vehicles
  • Some Conversion Examples
  • PHEV Conversion Decisions
  • Your Chassis Makes a Difference
  • Your Batteries Make a Difference
  • The Procedure
  • How Much Is This Going to Cost?
  • 5 Power Trains and Designing Your PHEV
  • How Does That Hybrid Electric Car Work in the First Place?
  • Types of Hybrid Drive Systems
  • Series Hybrids
  • Hybrid Electric Vehicle Parallel Design
  • Series-Parallel
  • Designing Your PHEV: Choosing a Mounting Method
  • Hybrid Electric Vehicle Drivetrain Components and System Details
  • How to Make and Design That PHEV
  • Classic Mounting Method
  • Alternative Mounting Method
  • Drivetrains
  • Difference in Motor vs. Engine Specifications
  • Design Your EV
  • Calculation Overview
  • Power Electronics and Electric Machines
  • Parasitic Loss Reduction
  • Buy Your EV Chassis
  • Why Conversion Is Best
  • The Other Side of Conversion
  • Keep Your Needs List Handy
  • Buy or Borrow the Manuals
  • Design That Prius as a PHEV!
  • 6 Engines and Electric Motors in the PHEV
  • Internal Combustion Engines
  • Fossil Fuels
  • Integrated Motor Assist on the Hybrid Electric Cars
  • Manual Integrated Motor Assist
  • Electric Motor
  • Voltage
  • What Is So Great about an Electric Motor?
  • DC Electric Motors
  • DC Motors in General
  • DC Motors in the Real PHEV World
  • Motor Case, Frame, or Yoke
  • Types of DC Motors
  • Series DC Motors
  • Shunt DC Motors
  • Compound DC Motors
  • Permanent-Magnet DC Motors
  • Brushless DC Motors
  • Universal DC Motors
  • AC Electric Motors
  • Transformers
  • AC Induction Motors
  • Polyphase AC Induction Motors
  • Wound-Rotor Induction Motors
  • Today’s Best PHEV Motor Solution
  • Conclusion
  • 7 The Controller
  • Controller Overview
  • Solid-State Controllers
  • Battery Management Systems
  • BMS Technology Complexity and Performance Range
  • AC Controllers
  • Elithion Controller Package
  • Selector
  • Separate High-Voltage Front End for Controller
  • DC Controllers
  • 2CH00xxx BMS Controllers CAN Specs
  • CAN Bus Protocol
  • CAN Tools
  • Transmitted CAN Messages
  • CAN Displays
  • Standard Traction Pack Messages
  • BRUSA Charger Control Message
  • Battery Management System (BMS) Controller
  • Received CAN Messages
  • Contactor Control Message
  • Request and Response CAN Messages—PID Support
  • Conclusion
  • 8 Batteries
  • Battery Overview
  • Active Materials
  • Overall Chemical Reaction
  • Discharging Chemical Reaction
  • Charging Chemical Reaction
  • State of Charge
  • Equalizing
  • Outside Your Battery
  • Basic Electrical Definitions
  • Voltage
  • Current
  • Power
  • Efficiency
  • Battery Capacity and Rating
  • Power Density (Orgravimetric Power Density)
  • Energy Density
  • Volumetric Power Density
  • Battery Performance
  • Other Factors Regarding the PHEV Battery
  • Battery Installation and Maintenance Guidance
  • Safety
  • Dynamometer Testing of PHEV Conversion Prius Vehicles Using A123 Systems
  • Today’s Best Battery Solution
  • Tomorrow’s Best Battery Solution—Today
  • USABC Continues to Come to the Rescue
  • The Big Picture on Batteries
  • Battery Types
  • Conclusion: The Future Is Amazing!
  • Lithium Ion and Nickel–Metal Hydride Are the Current Battery Technology Success Stories, but Lead Is the Least Expensive to Get the Job Done Today
  • 9 The Charger and Electrical System
  • Charger Overview
  • Battery Discharging and Charging Cycle
  • The Ideal Battery Charger
  • Manzanita Micro Moving from Electric to PHEV Too!
  • Other Battery-Charging Solutions
  • Rapid Charging
  • Replacement Battery Packs
  • Beyond Tomorrow—V2G
  • What’s the Point of Charge Control?
  • Charge Control Hardware
  • V2G Reports That Can Be Generated for Consumers
  • The Real-World Battery Charger
  • The Manzanita Micro PFC-20
  • Elithion Charger
  • Your PHEV’s Electrical System
  • Main Contactor
  • Main Circuit Breaker
  • Safety Fuse
  • Safety Interlock
  • Low-Voltage, Low-Current Instrumentation System
  • Wiring It All Together
  • Wire and Connectors
  • Connectors
  • Control Connector C4227A—Ford Escape Hybrid PHEV
  • HV Connector C4227C
  • Contactors
  • Routing
  • Grounding
  • Conclusion
  • 10 Plug-In Hybrid Electric Vehicle Conversion
  • Conversion Overview
  • What’s the Objective?
  • Before Conversion
  • Conversion
  • PRIUS+ History
  • Battery Pack
  • Lead-Acid Batteries
  • High-Voltage Circuit
  • Colors of High-Voltage Wiring
  • Electric Vehicle Charger
  • Toyota-Related Controls
  • Battery Tap Emulator Board
  • Control Board
  • Battery ECU SOC Spoofing
  • Installing the CAN-View
  • Disassembly of the Dashboard
  • Simple CAN Bus Scanner
  • CAN-View Version 4
  • CAN-View Configuration
  • OEM HV Battery Modifications
  • Component Locations
  • Names and Functions
  • Battery Cooling System
  • Battery HVAC
  • Mount PFC Charger
  • Install Battery Box
  • Interlock Box
  • Regulators
  • High-Current System
  • Test Data Display
  • Paint, Polish, and Sign
  • Put Yourself in the Picture
  • 11 Maximize Your Plug-In Hybrid Electric Vehicle Enjoyment
  • Licensing and Insurance Overview
  • Getting Licensed
  • Getting Insured
  • Safety Footnote
  • Driving and Maintenance Overview
  • Driving Your PHEV
  • Caring for Your PHEV
  • Battery Care
  • Lubricants
  • Checking Connections
  • Emergency Kit
  • Will This Conversion Affect My Warranty?
  • Cell Board Troubleshooting: Diagnostics and Repair of Cell Boards for Standard Battery Management Systems
  • Observing Behavior
  • Testing without a Test Fixture
  • Testing with a Test Fixture
  • Replacement
  • 12 Sources
  • Less Is More
  • Clubs, Associations, and Organizations
  • Manufacturers, Converters, and Consultants
  • Suppliers
  • Notes
  • Index