Gas To Electric Conversion Experience At CIT-Day 5

What We Learned From An Automotive Engineer Who Specialized in Car Modifications And What Is Required To Prepare An Electric Car For EV Registration

After the mammoth effort of Day 4, Day 5 was an important all theory day. In Australia, registering a diy Electric Car Conversion is a lot more complex than in many parts of the world. My understanding is that Australia has one of the most strictest and complex modified car registration and compliance processes in the world and this complexity has increased in recent years. To explain the compliance process required to for EV registration in New South Wales (NSW), Australian Capital Territory (ACT) and Victoria, we had John Wilson from AKZ Vehicle Engineering come and talk to us.

Topics discussed were:

• the various legislation relevant for EV registration (in Australia, particularly NSW, ACT and Victoria);
• what John Wilson looks for when checking a DIY Electric Car Conversion for compliance;
• suggestions of what your Electric Car should have; and
• the process you should follow.

After John Wilson’s talk, we had a quick discussion about what we were going to do next with the Gas to Electric Conversion on the buggy. We were still waiting on delivery of parts such as the pot box and contactor. There was a bit of discussion about the interlock which would be a micro switch. This would cut the control circuitry when the vehicle was plugged in for charging. The socket would have a flap which would be open when the plug was inserted into the socket (thus opening the micro switch, taking it out of its normally closed state, cutting the control circuitry)

Part of what was on white board (edited) at the end of the Gas to Electric class on 23 March 2012

We also discussed the pulley arrangement and it was determined that the Electric Motor would have 3 pulleys and the Gearbox/Differential would have 2 pulleys. The 3 pulleys on the Electric Motor can be aligned easily on the Electric Motor shaft because there was an easy to use adjusting mechanism on it that permitted it – a feature on this Electric Motor. This is not a common feature in general.

Various Legislations Relevant for EV Registration (for Australia, particularly NSW, ACT and Victoria)

The vehicle standards bulletin is the national guideline for light vehicle construction and modifications. However, the jurisdictions of NSW, ACT and Victoria have different requirements when a modified car is registered. Electric Cars are modified cars and require an engineering report from a recognized engineering signatory like John Wilson.

As an example, cars from 1996 and on later need to be crash tested. For diy Electric Car Conversions, this means if a post 1996 donor car is used, it needs to comply with crash tested. In Victoria, this means an example of your diy Electric Car needs to be crash tested (ie. you need to build 2 electric cars – 1 for crash testing and the other so you can drive it after registration). In NSW and ACT, you need to apply and be granted a concessional certificate for the relevant Australian Design Rule (ADR). However, in reality, engineering signatories are not confident in signing off on a post 1996 car unless it has been crash tested. There are complex legal reasons behind this.

In the Australian Capital Territory, a converted Electric Car will need a modification plate fixed to the car which details the modification. The engineer’s report of the approving signatory will need to attach color photos of the Electric Car Conversion.

When doing various calculations in relation to occupants, a person is considered to be 80kg (around 160 pounds) and carries 20kg (around 40 pounds) of luggage.

In general, cars with Internal Combustion Engines (ICE), if another ICE is installed that has over 20% more power, then it will need upgraded brakes. With Electric Car Conversions, it is best to get the brakes tested, since the power rating of an Electric Motor is not comparable to the quoted power rating of an ICE. Usually, Electric Motors are rated at continuous power and peak power and this power is often present at normal speeds. ICE are rated at peak power, but often this peak power is at some really high speed which most people won’t drive at in their normal course of driving.

What John Wilson Looks For When Checking A DIY Electric Car Conversion For Compliance

Here is a portion of what John Wilson looks for when checking an diy Electric Car Conversion for compliance. This is not a complete list, but here it goes:

• tires must be of correct rating;
• batteries must be secure and ventilated appropriately;
• when testing the brakes, the brakes must be effective when a force of under 450 Newtons is applied to the brake pedal;
• the mass  (or weight) on the front axle and the rear axle must be under what the manufacturer allows, otherwise, there is another process the vehicle must go through to ensure that axle and chassis can carry the load;
• anything above 240 volts will require a certificate for safety and earth leakage to ensure the Electric Car is safe for anyone in the vehicle and working on the vehicle;
• best to have high voltage wires tested and tagged (this tagging process is an Australian process which checks if wires are safe);
• batteries are electrically insulated such that if spanners were left lying around, it will not cause short circuits;
• batteries are securely fastened;
• when car is plugged in for charging, the car cannot be driven away;
• signage to indicate high voltage battery pack and high voltage components;
• hazard signs inside bonnet;
• high voltage circuits are compartmentalized from low voltage circuits;
• switches have sufficient cooling around them;

Suggestions On What Your Electric Car Conversion Should Have

Here is a sample (not complete) list of what your Electric Car Conversion should have: (A complete list can be sought from AKZ Vehicle Engineering)

• a battery range guage;
• an alert light to indicate low vacuum – this is in relation to the vacuum assisted brakes and the associated vacuum pump;
• use soft mounted motor mounts;
• have a circuit diagram drawn up;
• ensure the car is easy to drive such that it is intuitive for someone who is not a car enthusiasts and only uses a car to go from A to B;
• use a donor car that has a good resale value so that you have a chance of selling your Electric Car and minimize depreciation losses;

The Process You Should Follow

When doing your Electric Car Conversion with the view of getting EV registration for it (in Australia, particularly, New South Wales, Australian Capital Territory and Victoria):

• check with an engineer that is a signatory for modified cars of what is required and what they will be looking for when you do your Electric Car Conversion;
• give the engineering signatory an overview of your project and follow their advise;
• carefully follow the requirements and regulations in your jurisdiction as this is vital for EV registration;
• avoid donor cars built from 1996 and after 1996 (unless you want to build an identical example and submit it for crash testing);
• avoid cars with air bags – it complicates the paperwork (in Australia – could be different in other countries);
• expect to pay at least $2,000 Australian Dollars (which is around USD $2,000 depending on the exchange rate of the day) to get an engineer’s report so that you can register your Electric Car;
• choose a donor car that has a high resale value and that is fairly easy to convert;
• ensure your donor car is rust free and that the chassis is in great condition and not a written off car;
• best to get a donor car that was already registered in the past – just makes the process so much easier;

Summary

In Australia, doing an Electric Car Conversion involves doing things technically correct and also getting the paper work done right.  This is vital when you want to get EV registration. Australia probably has some stringent rules compared to many parts of the planet. If you are not in Australia, ensure you know the rules, regulations and requirements in your jurisdiction. Ensure you plan and consult with the appropriate authorities and plan your project properly. This will help reduce a lot of headaches down the track.

This is Crazy Al signing out

P.S. Next week is Day 6 where we plan to get the Electric Motor, pulleys and v-belts or sorted out.