Jun 18

Mitsubishi knows full-well that it may be a possibility, as they themselves have stated recently that lithium demand will outstrip supply as early as 2015. While we all expect and hope that prices will fall as production and popularity of EVs increase, prices could possibly rise instead, forcing us to other automobile alternatives (air-compression technology perhaps – see http://www.mdi.lu/english/). With such a demand on batteries worldwide for all sorts of applications, the implications pose new challenges to make better more efficient batteries using less lithium.

And competing countries are getting the edge over the US, who seek funding to stay ahead of the battery pack -http://earth2tech.com/2008/12/18/us-tech-companies-unite-for-car-batteries-seek-gov-aid/.

Where to get more lithium? Bolivia may come to the rescue – if only they can sort their internal political/economic issues first…

http://www.guardian.co.uk/world/2009/jun/17/bolivia-lithium-reserves-electric-cars

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Jun 18

The guard on my car needs a fix after a bump – oops – a simple job one would expect, but shopping around for a good panel beater is difficult as most don’t want to guarantee their workmanship on anything that could bring on the slightest hint of rust. I have a spare guard but it has spot rust in a corner. The little dent can be hammered out and re-sprayed. A recommended panel beater turned out to be indolent and over six weeks promised the world and offered nothing, except personal comments about my looks, boobs, etc. I’m lucky I guess; a friend left his EV with a panel beater recently who drove it around happily, not caring for the ‘fuel empty’ alert and in so doing, wrecking a couple of the batteries.

It’s a bit of a battle in a bloke’s world – whaddya do? Anyway, at least Nathan is good at cutting holes and has done an excellent job on the car – he knows what’s important and takes advice on-board instead of saying ‘I know better than you’ like a lot of fellas do. As he’s said, we’ve both learned a lot in the past year.

Bodgy mounting? No, because it's mounted on the inside firewall and easily accessible.

Bodgy mounting? No, because it's mounted on the inside firewall and easily accessible.

‘Mounting my Charger’

Me being a picky, persistent and annoying person at times, (okay okay, often), I didn’t want the Zivan to be mounted somewhere awkward and intrusive. The shape of the car is restrictive but clues on where to place stuff were staring me in the face. Some time ago I said, why not mount it in the pillar? After some research and legality-checking, Nathan agreed it could be a good place so I mocked up a dummy Zivan. Always mock up components if you have space issues! The Starion pillar has a kind of natural venting which is assisted by a small fan. It’s still easy to reach the Anderson connector should I need to. Oh, and the DC-DC is mounted on the opposite pillar – neat.

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Jun 05

News in from Otmar – the high-powered motor-controller maker has found new manufacturing feet for his famed Zilla controller. Double the top current-handling of my Curtis, the Zilla fills a much-needed hole in the EV market in the high-performance end. With water cooling built into some models, these things when fitted into a sports EV will give the Tesla a run for its money.

From the DIY Electric Car forum last month…

The Zilla will return later this year.

My production crew has been busy finishing up the last orders that I accepted in September. Meanwhile my engineer Arthur and I are finishing the design changes needed for effective higher volume production. The automated test equipment that Arthur built will support volume production and has already increased the quality of Zillas going out the door. The improved Hairball code I’ve been working on ran today for the first time in my 914 and promises to increase reliability as well as make diagnostics easier.

I am in talks with a very qualified licensee, and although we have not signed any formal agreements yet, we seem to be finding common purpose and I expect things to be well established soon.

I apologize for the delay. My less than ideal health and my possibly unreasonable requirement for quality has not been conducive to moving faster on this path, but it is encouraging to see the transition coming to fruition.

The waiting list on our website continues to grow and I hope the new manufacturer will be contacting those of you on it soon.

Thank you all for your patience, – Otmar, http://www.cafeelectric.com/, The Zilla factory.

More threads here:

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Jun 02

Reports have been coming in of a new type of air-charged battery which could provide up to ten times the energy storage of a conventional lithium cobalt battery. Called the STAIR (’St Andrews Air,’ where it was developed at Scotland’s University of St Andrews), it provides improved capacity via a porous carbon exchange cell lattice which they say is a chemical-free lightweight battery technology ideal for electric vehicles.

Oxygen exchange battery

Oxygen exchange battery

It’s early days yet, but developers aim to get a ten-fold increase in storage capacity. A reagent in the battery draws oxygen from the air during the discharging phase and the carbon lattice interacts with the air to achieve an efficient charge/discharge cycle with little degradation over time, unlike what one would typically get in your regular chemical exchange systems.

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May 22

The Nissan Nuvu (aka ‘new view’) announced some time ago may finally be arriving in Australia next year to compete against the Mitsubishi MiEV (and possibly Toyota iQ if they sort their red tape with the government) in what is gearing up to be a new spark of electric auto competition. An alternative to the Nissan Cube, this little cutie will be in a price range to match the MiEV and it is expected fleet and government sales will take up a large chunk of first shipments.

The Nissan Nuvu

The Nissan Nuvu

This design features a pretty windscreen/roof overlay of solar collectors integrated into a conduit that leads to the battery pack…
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May 18

While Nathan and I have had to work our day jobs, we’ve managed to finish other cars for our clients (Nathan doing the heavy stuff, me with some wiring and CAD diagrams, etc.) and such demands pushed back my own project, but now Nakey has more time to help my car to completion.

We’ve also had many queries and explanations asked of us in relation to how it all works – and providing those answers has taken considerable time in itself. Now that my car is near completion, I need to take a break, a long one while the body-panel experts fix areas one may consider trivial but I see as important.

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Apr 11

My Airpax breaker, the main breaker switch, now has a busted switch-arm (I’ll save you the painful images). Just a few test throws under tension, the supposedly strong Bakelite switch arm shattered. The Airpax breaker is expensive, and we’ll have to see if it’s still under warranty as I paid for this some time ago. Considering the breaker is there for safety, it’s a pretty serious failure.

I suspect the cable linked to it and the pivot bend may not have been aligned on quite the same axis and hence some side-ways pulling met with plastic stress thus causing the break. Anyway, another delay. One would assume that such a switch should be strong enough to handle a quick throw.

LEDs Flashing

Blinkin' good

BMS LEDs Now A’flashin’

When I first received the BMS modules, I noticed that Ross Blade hadn’t included charge status LEDs. I bought a bunch and soldered some on but my error at the time was to solder them on the wrong way around, i.e. instead of shutting off when the battery reached peak-defined charge, they stayed on while discharging. The polarity on the modules was not indicated; I had guessed the correct positive end, though Nathan was convinced otherwise at the time (men are always right, right?) so I soldered them the other way.

Fine? Well no, but in a sense, yes…
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Apr 02

On display at Sydney’s Darling Harbor is the new all-electric MiEV ‘production’ display vehicle.

MiEV dashboard.

MiEV dashboard... mmm... round, we like round...

Although I haven’t had a chance to see it yet, a colleague from the office did and here is what he had to say…

The Mitsubishi i-MiEV electric car is on display today in Darling Harbor, I stopped in to take a look this morning. They had some example batteries and a motor on display too.

It’s on a stand, and you can’t get close enough to touch it or see what the internal space is like, or how much boot space there is.

According to the Mitsu sales guy, they will be available in 2010, or maybe 2011, as they are still working on the fast charge system. The web page claims 30 minutes fast charge time to 80% capacity, but he quoted 1.5 hours today. The batteries are Lithium Ion (cobalt), not Lithium Phosphate, so I would guess they are still developing the systems to ensure that charging is safe and the batteries cannot overcharge and overheat. Li-Ion have higher energy density, but Li-Po are safer.

There are 2 charge sockets, the fast charge on the nearside under a petrol-type fuel filler flap, and an ugly looking domestic socket on the offside, both on the rear wings. I asked if the domestic charger (7hrs to 100% charge) could take 15A or 20A from an appropriate socket, but he couldn’t answer. I suspect it is limited to 10A.

The motor is 46kW, liquid-cooled, and looks like it is probably 3-phase induction. A single fixed-ratio reduction gearbox driving the rear wheels, reverse is by electrically reversing the motor. The ‘gear shift’ has 3 modes – ‘D’, ‘E’ and ‘B’ – which seem to be all about how the car responds when not accelerating:
D – Drive will simply coast with foot off the accelerator
E – Economy has mild engine braking (regenerative) so the car slows down slightly with foot off
B – Brake has strong regenerative braking – like using a lower gear to maintain speed when descending hills

If I understand it right, there is no actual difference in acceleration or performance under power between the 3 modes, it is purely about how much engine braking effect there is.

Claimed stats are top speed 130kph and 160km range (ie, 100 miles for the US market), 10 year battery life. No 0-100 time quoted, but reported to be quite nippy and ‘fine for in-town’ (so it should be with full torque available from 0 speed.)

Overall it’s a small car but not a tiny car, although somewhat narrow as is common for many domestic Japanese cars (for fitting down the narrow streets.) 4-seater, no idea of the (front??) boot capacity (but it doesn’t look very big). Layout is rear engine, batteries under the floor in the middle and rear of the car.

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Mar 26

Now that heading is such a bad joke! I’ll just have to elaborate, sorry, but Better Place have had a few more musings lately, one being that the idea of fast charging stations will be to cater for cars that are leased only (a ‘Who Killed…‘ deja vu again?). The idea is to lease the vehicles on a per-kilometer plan, similar to a cellphone plan.

Park 'n charge, while you run out of energy shopping for the kids.

Park 'n charge, while you run out of energy shopping for the kids.

Better Place would be the provider and keep ownership of the vehicles and battery packs, and implement charging station infrastructure and battery exchange depots up and down the east coast of Australia. GPS locators as a theft guard will be incorporated into cars (and/or batteries?) and intelligent charging points linked to electricity suppliers to manage the grid load. Batteries can be swapped over on-the-fly (personally I prefer the concept of inductive charging, a stinking big transformer under the surface where a car is parked and an inductive loop created for fast charging (sort of like the Magnum inductive charging systems seen elsewhere but on a bigger scale) – imagine the amount of power and speed of charge, provided the batteries can handle it!).
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Mar 12

I must apologize for all these delays! Being a small outfit, the Echo has taken up considerable time but it looks very good now and will be delivered to the client soon. The BMS has been upgraded and looks pretty neat with the cosmic blue charge active LEDs added.

My health has been a bit of an Achilles Heel, along with work pressures and the usual stuff, but I am patient and all good things come to those who are patient. People are begging to see my car now and I much prefer to take things slowly so we can get it right, first time around without extra work fixing a bad mistake.

On other matters, my PC died, the HDD died and what’s worse, the backup HDD died! Sheesh, ah well, ‘them’s the brakes’ as they say, (and at least that part of the car is complete – although I’ve discovered we may not need the additional vacuum tank, the master cylinder has plenty of vacuum!). So it’s off to the local computer markets to get myself some new parts and build up something faster.

Time – sheesh, wish I had more.

Meanwhile, Nathan drove the Echo down the road to get the air-con re-gas done and the car drives like a treat, no pull of heavy batteries and the weight only comes in around only 175kg above the original tar (people-less) weight! The zippy 8 inch motor has plenty of grunt and so far uphill climbs have been a breeze, even without Curtis water cooling (the Curtis just has a thick aluminum block bolted underneath, and sandwiched with silicon paste). A strange above-earth potential voltage issue was solved by un-grounding, i.e. isolating the Curtis with shielded spacers. Normally one would bolt the Curtis to some bulkhead on the car for heat-sinking. The slight capacitance could have interfered with the Echo’s computer so we took no chances. The Echo also has the Zero Start water boiler (shown in a previous video) and this is way-better than the small electric element implanted in my heater unit (and a lot less work, i.e., the dash did not have to come out).

Anyway, enough prattling from me, back to work. Photos in the next post.

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