Series Wound DC Motor

Series Wound DC Motor

A Brief Description To Help You Understand Series Wound DC Motors As Used In Various Electric Car Conversions

Series Wound DC Motor Housing And Field Windings

Series Wound DC Motor Housing And Field Windings

What is a Series Wound DC Motor?

A Series Wound DC Motor is an Electric Motor where the magnetic field is made up of electro magnets, which are wound in series to the armature. Brushes are used to make connection with the armature and on the armature, there are commutators to perform the commutation. A typical characteristic of Series Wound DC Motors is that it’s speed varies with load, so if there is no load applied to the motor, it will speed up and can self destruct. Conversely, if as a load increases, the speed of the motor slows down.

Series Wound DC Motors are commonly used in Electric Car Conversion projects as it is easy to buy off the shelf the motors and compatible controllers at a reasonable price. They also give reasonable performance and because torque (which helps with acceleration) is proportional to the current squared, they make fantastic drag racing motors.

What are common features of Series Wound DC Motors?

Series Wound DC Motor Armature With End Cap

Series Wound DC Motor Armature With End Cap

The common features of  Series Wound DC Motors are:

  • Field Windings are electrically connected in series with the armature;
  • Low resistance field windings;
  • Use brushes to supply current to the armature;
  • Armature has commutators;
  • Very good torque characteristics compared to other Brushed DC Motors, hence, often used for applications where high starting torque is required. Series Wound DC Motors were often the traction motor of choice for Electric Trains;

What are some examples of Electric Cars and Electric Vehicles using Series Wound DC Motors?

There are many examples of Electric Car Conversions that use Series Wound DC Motors. The donor cars range from Porsches, BMWs, Chevys, Fords, Dodges, Volkswagens and many many more. Many of the cars are not small nor light. EVAlbum has many examples of such cars. The following is a sample of Electric Car Conversions using Series Wound DC Motors:

More examples of Electric Cars and Electric Vehicles using Series Wound DC Motors can be found at EVAlbum.

 

What are the advantages of Series Wound DC Motors when used in an Electric Car Conversion?

Some of the advantages of Series Wound DC Motors are:

  • High torque and acceleration compared to other Brushed DC Motors;
  • Fantastic for drag racing applications.
  • Plenty of other DIY Electric Car Conversions have been done using Series Wound DC Motors.

 

What are the disadvantages of Series Wound DC Motors when used in an Electric Car Conversion?

Some of the advantages of Series Wound DC Motors are:

  • Controllers which permit Regenerative Braking (Regen) are very difficult to make and/or purchase;
  • Brushes are a wear item and need replacement when worn;
  • Sparks and arcing can happen from the brushes.
  • Interference to TVs, radios etc can result due to RF noise from the brushes.

Check out Motors For Electric Cars Family Tree for more Electric Car Motor information.

How You Can Insulate Yourself From The EU Ban On Iranian Oil

How You Can Insulate Yourself From The EU Ban On Iranian Oil

Just before the finalization of the EU Ban On Iranian Oil, I was reading an article titled “EU readies ban on Iran oil imports, central bank sanctions“. Just to keep things in perspective, ElectricCarConversionBlog.com is not in a position to comment about politics so I will steer away from political comments. I don’t want to comment whether the EU Ban On Iranian Oil is the right or wrong thing to do, but I will make comments to its effects in relation to energy and cars. In that article, there was a sentence that got my attention: “Greece, in particular, is heavily dependent on Iranian oil — it sources nearly a quarter of its oil imports from Iran — and has argued that it needs time to find alternative sources.

What Does “It Needs Time To Find Alternative Sources” Mean?

This part of the sentence really grabbed my attention. Why does Greece need time to find alternative sources? Is this sentence for real? I think that sentence is a load of trash. To demonstrate how you can insulate yourself from the EU Ban On Iranian Oil, let’s consider a few things. We live in an age where people can generate electricity from renewable sources like solar, wind and hydro and we also live in an age where ordinary people are doing their own Electric Car Conversions so that they can drive on the energy derived from renewable sources. In fact Greeks like Nikos Giakoumelos have already done their own Electric Car Conversion. He even has a short video showing how the Electric Car Conversion was done.


Greek did Electric Car Conversion and can now insulate himself from the EU Ban On Iranian Oil

 

I realize not every Greek drives a car and many ride bikes or scooters. According to evalbum.com , Manos Sotiropoylos has done an Electric Bicycle Conversion and Theo has a modified Electric Scooter. I’m sure there are more Greeks who have done Electric Car Conversions or other EV Conversions and I could imagine that the typical commute amongst most Greeks would be well within the range of these Electric Vehicles. With these vehicles not relying on oil, why does Greece need to find alternatives? There are Greeks who are already using alternative powered vehicles known as Electric Vehicles.

I guess the next question is how does Greece source their electricity?

Greece sources its electricity from renewable sources such as hydro, thermal, solar and wind. They also source electricity  generated from coal and oil. Greece also has a lot of sun so they could add more solar panels to further utilize the sun they receive so that they don’t have to rely as much on oil to generate their electricity. By adding more solar panels to their existing array of solar panels, Greece can effectively source their own electricity and survive the EU Ban On Iranian Oil.

With transport, Greece already has people experienced with Electric Car Conversions and Electric Vehicle Conversions so they effectively don’t really need time to find other alternative [oil] sources. They already have other sources of Electricity Generation and people who know how to do Electric Vehicle Conversions which they can utilize fully.

Even though Greece wanted extra time to find alternative sources, it appears the Greek people already have the answers within in terms of energy generation and transportation, so effectively, they have the know how on how to insulate themselves from the EU Ban On Iranian Oil. All they have to do is mobilize themselves and do Electric Vehicle Conversions on a larger scale with their pioneers showing the way.

Conclusion

By doing your own Electric Car Conversion [because you can't wait for various car makers to produce one], your reliance on oil is reduced which will help insulate yourself from the EU Ban On Iranian Oil.

 

This is Crazy Al Signing out.

P.S. I would be interested to hear your comments and also would be interested in what articles you would like me to write. You can add your comments below. Thanks

First Electric Vehicle Charging Station Opens In Goulburn, Country NSW, Australia

First Electric Vehicle Charging Station Opens In Goulburn, Country NSW, Australia

Goulburn's First public EV Charging Station -> Goulburn Mechanical And Performance Centre

Goulburn's First public EV Charging Station -> Goulburn Mechanical And Performance Centre

With the increasing interest and usage of Electric Vehicles, Goulburn Mechanical and Performance Centre (Goulburn Motors) has responded. Goulburn Mechanical and Performance Centre which also sell gasoline (petrol) and diesel, as well as doing mechanical repairs, service and building high performance cars, have been a keen supporter of the development work I do on my Electric Go Kart and I have been fortunate to be able to use their fast charging system to quickly charge up my Electric Go Kart. This fast charging unit has permitted me to fully charge the batteries in around 20 to 30 minutes. This is a lot quicker than the battery chargers I have seen sold in automotive shops. With the convenience shop attached, you can buy snacks, food, drinks and magazines whilst you wait for charging to complete.

In fact, Tony Atra who is the business owner even came down to Summernats 2012 and brought a crowd with him when he visited my Electric Go Kart. He also took a keen interest in the Electric VW Beetle that was next to my Electric Go Kart and is interested in Electric Vehicle Technology and how he can serve owners of Electric Vehicles.

Electric Go Kart Being Fast Charged At Goulburn Mechanical And Performance Centre

Electric Go Kart Being Fast Charged At Goulburn Mechanical And Performance Centre

With Goulburn (in NSW) located along a major route used by many to travel between major cities like Sydney, Canberra and Melbourne in Australia, Goulburn Mechanical And Performance Centre’s Business Development Manager, Richard, is very interested in upgrading their fast charging station to accommodate the higher voltage Electric Cars like seen on the Mitsubishi i MiEVs. Richard also looks after 5 other gas stations located strategically between Canberra, the South Coast and Sydney and is also interested in installing fast charging stations in them to better serve the Electric Car and Electric Vehicle community, especially with many people driving between Canberra, Sydney and the South Coast. Whilst, the fast charging units for the higher voltage Electric Cars are being sorted, commuters are encouraged to bring their mobile charging cords when they want to charge up in Goulburn.

Goulburn Mechanical And Performance Centre, located on 62-68 Clinton St, Goulburn, NSW, Australia.

View Larger Map

Once again, I would like to thank Goulburn Mechanical and Performance Centre for supporting my Electric Go Kart and who continue to help me with the development work I’m doing to it.

This is Crazy Al signing out.
P.S. Please subscribe to my RSS feed to keep up to date with my latest blog posts.

Electric Go Kart Story-Part 8

Electric Go Kart Story-Part 8

Doubling The Voltage To The Modified Electric Starter Motor To Increase Speed To The Electric Go Kart

FunkyCarSkins-ElectricCarConversionBlog Electric Go KartWith 24 volts

FunkyCarSkins-ElectricCarConversionBlog Electric Go Kart With 24 volts

In Electric Go Kart Story – Part 7, I discussed speed controllers and motor controllers. Before getting one, I wanted to know if I could double the voltage to the modified Electric Starter Motor and run on 24 volts. A week after Summernats 2012, the Electric Go Kart of Funky Car SkinsElectricCarConversionBlog.com was tested to determine if the modified 12 volt Electric Starter Motor could handle two 12 volt batteries being applied in series to deliver 24 volts.

The theory being tested was that if the voltage was doubled, the speed would roughly double, since with Permanent Magnet Electric DC Motors, speed is roughly proportional to voltage and acceleration is roughly proportional to current.  The intention was to just double the voltage.

I first took the Electric Go Kart for a test drive in the 12 Volt configuration which was known to work. I was able to drive it and drift a bit with no dramas.

 

I added another 12 volt battery in series so that the Modified Electric Starter Motor would get 24 volts.  It should be noted that the crude motor controller which I built in 2011 did not have any current limiting circuitry. It only did pulse width modulation (PWM) to control speed. The extra battery also meant extra weight and there was only room just next to the rear axle. With more weight on the rear axle, it would theoretically have been harder to drift.


Funky Car Skins - ElectricCarConversionBlog.com Electric Go Kart with 24 volts pumped through it. I was driving it in my new racing overalls and gloves which I got from Stable Karting.

When I took the Electric Go Kart for a drive with the new configuration of 24 volts, it had quite a bit of pick up, was noticeably faster and I was able to do a nice drift when doing a U turn. The person filming the above video did not expect this Electric Go Kart to take off as quick as it did. As you can see, by the time he made it to the corner of the building, I had already turned around (more like drifted around doing a 180) was starting to move in the opposite direction until I lost power.  The Modified Electric Starter Motor ended up smoking up. Within seconds of driving it with 24 volts, the kart went from being a nice and fast with the ability to drift to a motor that was cooked. I cooled the motor by pouring water over it which seemed to cool the modified Electric Starter Motor fairly rapidly.

Later on, I did try driving the Electric Go Kart, but this time on 12 volts, but the modified Electric Starter Motor was not the same.

What are some of the lessons learned:

For starters, it should be noted that Electric Starter Motors are designed to run for only a short time, typically up to 10 seconds before needing a rest for around 1 minute. With the way I use the Electric Starter Motor, I’m exceeding it’s designed and intended capability, so no warranty there.

Starter Motors don’t have any cooling features. Notice how there are no cooling fins, cooling fans or liquid cooling features on them. It is no surprise then that the modified Electric Starter Motor used to power my Electric Go Kart often gets very hot after a few minutes of driving.

Commercially available Electric Motors for Electric Vehicles typically have a cooling fan or have liquid jackets for liquid cooling capabilities.

A number of people including some at Summernats 2012 and the 2011 Canberra International Electric Vehicle Festival have made various suggestions on how I could cool the Electric Starter Motor. Here are some of the suggestions:

  • Put some cooling fins (imagine a large washer that fits over the cylindrical casing of the modified Electric Starter Motor) around the circumference of the modified Electric Starter Motor;
  • Wrap the modified Electric Starter Motor with copper tubing and have heat sink compound smeared between the copper tubing and casing of the modified Electric Starter Motor. Then have water circulate through the tubing. This would require a little pump and a small radiator to ensure a supply of cool water to the modified Electric Starter Motor;
  • Fabricate a water jacket around the Electric Starter Motor;

My new sponsor, Goulburn Mechanical and Performance Centre is in the process of sourcing a bigger Electric Starter Motor for me to modify and attach to the Electric Go Kart.

This is Crazy Al Signing Out.

P.S. I would be interested in your thoughts about which way you think I should go with Electric Starter Motor on the Electric Go Kart which you can add in the comments section below.

Check out the other parts to the Electric Go Kart Story:

Part 1 – What Inspired Me To Do An Electric Go Kart Conversion

Part 2 – Taking Action – Modifying An Electric Starter Motor

Part 3 – When The Rubber Hits The Ground

Part 4 -Extra Parts Added To Electric Go Kart – Adding A Touch Of Professionalism

Part 5 – Replacing Electrical Switches & Electric Motor

Part 6 – Building A Motor Controller For Electric Go Kart

Part 7 – What I’m Looking For When Upgrading The Motor Controller On The Electric Go Kart

Part 8 – Doubling The Voltage To The Modified Electric Starter Motor To Increase Speed To The Electric Go Kart

 

Mitsubishi i miev Electric Car Review

Mitsubishi i miev Electric Car Review

Mitsubishi i-MiEV Electric Car Left Front View

Mitsubishi i-MiEV Electric Car Left Front View

In early January 2012, I got the opportunity to test drive a 2010/2011 Mitsubishi i-MiEV Electric Car. In reviewing and test driving this Electric Car, I looked at how a typical city dweller would want to use it and if would meet these expectations. The review describes the criteria used and how the evaluation was made so it can be seen how I made the assessment and the conclusions drawn.

Value For Money

I felt that the Mitsubishi i MiEV is a bit over priced for what you get. Considering it is possible for a private person to do their own Electric Car Conversion on a similarly sized car for less and Mitsubishi, being an established car manufacturer, they should have access to resources, suppliers and since this Electric Car is being mass produced, they should be able to achieve economies of scale. As it is based on the Mitsubishi i which is a gasoline powered car, then a lot of the body parts, wheels, lights etc are already being mass produced so Mitsubishi should be able to leverage on the economies of scale as it is based on a highly popular car. In the past, I have been critical about the pricing of this Electric Car, but the demand for the Mitsubishi i MiEV far exceeds supply, which consequently allows the Mitsubishi i MiEV to command its high selling price. I have seen several i MiEVs on the road and although most are owned by corporations, there have been private individuals buying them as well. Although market forces permit the i MiEV to command this high price, I feel that Mitsubishi could have added extra value to the i MiEV such as a sun roof, sports wheels, body kit, rear spoiler, body hugging racing seats and a racing steering wheel.

Fun Factor

Inside the i MiEV, the cockpit is fairly basic. When cruising along and you want to quickly accelerate, the acceleration is phenomenal. It is basically almost instant and with the single speed transmission and wide torque curve, there is no waiting for kick down or shifting down. With the small body, it just zooms. Although, it is not a Tesla Roadster, Porsche or Ferrari, it leaves a lot of other cars on the road behind which can result in some amazed looks from others. However, if you are trying to accelerate as quickly as possible from a standing start, there is up to a one second delay from the time you stomp on the accelerator to the time the i MiEV moves. This is probably due to a soft start feature programmed into the controller to help prevent the Electric Motor from burning out and thus preserve the life of the Electric Motor. This feature did confuse me at first because other Electric Cars and Electric Vehicles I have driven had massive acceleration from a standing start. I have to admit that I did not want to hand the car back after I finished driving it. I would happily take this car home.

Practical

The i MiEV seats 4 full sized adults easily. The rear cargo space fits a lot of shopping and if you need more space, you can fold down the rear seats. The rear seats have a 50/50 split so you can fold down one seat and still seat 3 people. The batteries don’t intrude into the passenger compartment. Being based on a Japanese Kei car, the i MiEV was clearly designed to be practical in the busy and cramped streets of big city centers. Although, the range is up to 100 miles (160km), I suspect that in practical terms, it will be around the 62 mile (100km) range, unless you accelerate like a snail and avoid going up hill. This range is sufficient for the majority of city commuters where the majority would not do more than 50 miles (80km) from home to where ever they go and back home again. This probably explains why some of the charging stations at shopping centers have not been heavily used as most people who drive Electric Cars probably don’t need to use it and charging at home more than satisfies their needs.

Driving (From A Driver’s Perspective)



Mitsubishi i-MiEV Electric Car Test Drive

From a driver’s perspective, driving the i MiEV is nice and easy to drive. The A-Pillar does create some blind spots so you have to be a bit careful at intersections (like if you have to give way to traffic). This problem is not due the being Electric, but a problem inherited from the gasoline powered Mitsubishi i, which this car was based on.

i-MiEV Electric Car Driving Position

i-MiEV Electric Car Driving Position

When I was starting it, I just put the key fob in some compartment under the steering column, pressed the foot brake with the gear stick in P. I guess it would work in N as well, but I did not try that. Then I turned a switch (where the key would normally go) until the dash said ready. I found out from the owner’s manual that if the key fob ran out of batteries, there is an emergency metal key which you pull out of the fob. The switch to start the car, you pull the plastic cover off and insert the emergency key into it and proceed as normal.

The car behaves like an automatic car.  If the gear stick is in D and you don’t have the accelerator or brake pressed, the car creeps forward like a gasoline powered automatic car. I did not try it out when I had the gear stick in Eco or B. I tried to work out what the different modes on the gear stick do and have described them below:

i-MiEV Electric Car Gear Stick

i-MiEV Electric Car Gear Stick

  • P for Park;
  • R for Reverse;
  • N for Neutral;
  • D for Drive and it appears regenerative braking is not activated when the accelerator is released;
  • Eco for Driving – not sure about the regenerative braking behavior, but the car did slow down a bit quicker than when D was selected;
  • B for Drive and it appears regenerative braking is activated when the accelerator is released.

When I first drove the i MiEV I did not notice the regenerative braking when the gear selector was in B. After I was told, I paid attention to the braking behavior and you could notice the regenerative braking activate, but it was not as strong as I expected. If you look at the dash, and regenerative braking is happening, the needle indicates that it is charging. I feel the regenerative braking should have been stronger than what it is, but it appears Mitsubishi went for smoothness.

I found the digital speedometer useless when I was accelerating quickly 10mph (16km/h) to 50mph (80km/h) as the digits would flicker that fast since the acceleration under these conditions was phenomenally quick. I found myself letting go of the accelerator so that I could see how fast I was going and then stomping onto the accelerator again. I feel an analog speedometer (one with a needle) would have been better as you can see your rate of acceleration and know what speed you are doing at a glance. Once, you reached a steady speed, the digital speedometer is fine.

Performance

With a top speed of 81mph (130km/h), this exceeds many city speed limits. Most people in cities will not even get close to those speeds (legally). With 132 ft lb i.e. 180Nm of torque which is more than a number of 4 cylinder and some 6 cylinders gasoline powered cars, coupled with a small body, it means the acceleration is a lot quicker than many standard gasoline powered cars. With this type of acceleration, it is great from blasting away from traffic (provided you are rolling already).

Comfort

For a town or city car, the i MiEV is reasonably comfortable. It hasn’t got the nice luxury seats of the Rolls Royce 102EX Electric Car (which is basically a factory Electric Car Conversion done to a Rolls Royce Phantom), but feels no worse than a standard Ford,  Chevy or Toyota. Leg, shoulder and head room was sufficient (I’m 5’7″). I would have no problems driving this car for hours.

Mitsubishi i-MiEV Electric Car Specification

Body Type: 5 door small hatch, based on the Mitsubishi i kei car, so effectively, it is a factory Electric Car Conversion.

Curb Mass (Weight*): 2400 lb (i.e. 1080kg)

Motor


Mitsubishi i-MiEV Electric Car - video of Electric Motor and Rear Axle

Type: Permanent Magnet AC Synchronous Electric Motor

Power: 63hp i.e. 47kW (Mitsubishi literature did not specify if that figure was continuous or peak power)

Torque: 132 ft lb i.e. 180Nm

Location: Between the rear axle and rear passengers.

Motor Controller

Not specified.

Transmission

Single speed. Motor is situated in the back near the rear axle. This is a rear wheel drive Electric Car. The gear stick looks like an automatic and it even drives like an automatic, for example, if the gear stick is in drive and the foot is not on the brake, the car will move forward just like most gasoline powered automatic cars. This is different to DIY Electric Car Conversions I have driven that had manual gearboxes where the electric motor would turn when upon application of the accelerator pedal.

Battery

Chemistry: Lithium Ion

Storage Capacity: 16kWh

Location: Under the passenger floor

http://i.mitsubishicars.com/

Mitsubishi i MiEV Electric Car Charging Cord

Charge Time: 8 hours from a 220/240Volt, 15Amp power point. Quick charge outlets may charge up to 80% in 30 minutes. The charging unit is on board with a plug in points on the Electric Car.

Brakes

Front Brakes: disc

Rear Brakes: drum

ABS: Standard feature

Regenerative Braking: Available when gear stick is in ‘B’ position

Accessories

Steering: Power assisted

Heated Seats: Driver’s seat was heated

Traction control: Yes and there was a button to turn it off, but when I used it, I could not tell if the traction control was off or not.

Air Conditioning: Yes

Power Windows: Yes

Power Mirrors: Yes

Entertainment/Display: Premium touch screen head deck unit which incorporates AM/FM radio, CD player, SD card reader to play MP3s. Also incorporated was a GPS satellite navigation system.

Speakers: I counted 4 speakers (it could have more-just not sure). The in car entertainment unit claimed it had subwoofers. I did not bring appropriate music to test it, but the sound was fantastic.

Driving

Range: up to 100 miles i.e. 160km

Claimed Top Speed: 81mph  i.e. 130km/h

Pricing and Value For Money

In USA: from USD $27,990

In Australia: from AUD $48,000 which equates to approximately USD $48,000

I feel that this is rather pricey for a car of its size. Having said that, the demand for this car far exceeds the supply, hence, pricing is likely to remain as is. It would be cheaper to do your own Electric Car Conversion.

Summary & Conclusion

Mitsubishi have created a nice, simple, fun, easy to drive car that is durable, function able, and reliable. The performance is fantastic, particularly when accelerating from a low speed. When accelerating from a standing start, the software in the Motor Controller appears to purposely give a 1 second delay and I would say that this is a soft start option to prevent motor burnout and hence increase reliability of the Mitsubishi i MiEV. This is  a good honest car which in my opinion would suit the driving requirements of most city dwellers. After driving the i MiEV, I actually wanted to keep this Electric Car. It is a very nice car to drive and despite it’s expensive price, I can see why demand far exceeds supply.

Pros:

  • Practical 4 seater car;
  • Drives like a regular gasoiline powered car, but has massive acceleration (if it is rolling already);
  • Nice loud, quality stereo system. Good bass from speakers. Unfortunately, this feature is not marketed very well by Mitsubishi;
  • Touch screen for Navigation can be used even when driver is wearing racing Sparco racing gloves;
  • Suitable for city trips that the majority of motorists would do;
  • No smell from motor;
  • Silent motor which is fantastic if you are delivering pizzas at night or live in a neighborhood full of noise sensitive residents;
  • Regenerative Braking is a fantastic feature to have as it helps extend the range of your batteries.

Cons:

  • Price is rather expensive, but with demand far exceeding supply, it appears the price will stay high for the moment;
  • Although volume of the in car entertainment system was easy to adjust, adjusting the bass, treble and other speaker settings needs to be done via the touch screen which is unsafe to do whilst driving;
  • Thick A-pillar can obstruct visibility;
  • Digital speedometer means it is easy to get a speeding ticket whilst accelerating hard.

Scoring:

  • Value for money:      3/5
  • Fun factor:               4.5/5
  • Practical:                     5/5
  • Driving:                       4/5
  • Performance:          4.5/5
  • Comfort:                       4/5

This is Crazy Al signing out.

* Weight is technically not the same as mass. Weight is mass multiplied by gravity.

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