1. A Quick Look at the Road Ahead
and Life with an Electric Car
Phillip Crippen

2. Agenda
Welcome & Introduction
Buy vs. Build Options
Common Myths and Misconceptions
Learning to Live with Range Anxiety
Potential Roadblocks to mass Adoption
1

3. Buy vs. Build
$44k $25k $100k+
Volt (early 2011) Leaf (early 2011) Tesla (2008-11)
White Zombie (born 1994) VoltsRabbit (born 1991) e318ti (born 2010)
$15k $10k $15k

4. Build: e318ti
Donor: 1997 BMW 318ti, 207k miles, purchased Oct 2008
Factory Converted
Engine 4cyl 1.9l 9inch DC
Max HP 103 HP @ 100HP
6000RPM
Max Torque 133 ft-lb @ 115 @ 500A , 0-
4300RPM 5000RPM
Max RPM 6500 5000
Top Speed 140mph 80mph
Curb Weight 2950 lbs 3100 lbs

5. DC vs AC
DC AC
Torque ~Current ~1/Speed
Speed ~Voltage ~Frequency
Motor Brushes & Commutator Rotor cast, no rotating
Complexity for Wound Rotor wiring
Controller Simple (PWM) Voltage Complex, chopping DC
Complexity Control. into AC waves.
Regen Complex Default Regen
EV Setup Cost Low High (2x)
Typical EV Voltage 144VDC 360VAC
Battery Pack 12x12V 30x12V

6. Build: What Comes Out?
Lots of Greasy, Dirty Stuff
Radiator
Engine (!)
Exhaust
Gas Tank
Heater Core
Power Steering
Brake Boost

7. Build: What Goes In?
Cleaner, Drier Stuff
Motor
Controller
Batteries
Electric Heater
Elect. PS Pump
Vacuum Pump

8. Build: What’s Going on Under the Hood?
Two Layers under the Hood: Controls and Action
Controller
Batteries
“Gas Pedal”
Motor
Elect. PS Pump
Vacuum Pump

9. Build: What About the Other End?
Batteries and On-Board Charger
Charger
Batteries

10. Schematic
12V
115VAC From
<10> 144 VDC <10> PS1
R BK
R C3+C3+ BC1 C3-C3-
<2/0> <10> <10>
R R R BK
<2/0> C1+ CR+ CR- C1- Aux Batt
Rear Battery Box
<10> <10>
PF1 R BK
CF1 Donor 12V
300A K4
20A <12> <12> <12> Bus
Y Y Y IS1
<2/0> <2/0> <14> <14> <14> <14>
Heater R R R + K1 BK
<12> V <12>
Y Y Donor Key <14> <14>
K3
R R R 85 86 BK
KLK <12> <12> Wh To
Y
+ - Y
Com
Drive
R Bk
+ -
PS1 <14> <14>
NO + K2
R BK
12V To NC
Controls Potbox
<14> <14>
R + BK
Controller Fan
<12> K3 <12> R <14> <14> <14>
+RK4
87 30 Y BK
Donor Heat
From
Potbox <14> <14> <14>
L2 T2
K2 <2/0> K1 R BK
Vacuum
+ B+ 1 2 3 B- +
Controller Pump
<14>
Gnd
A2 M- BK
Vacuum
Switch
<2/0> <2/0>
<14> C1 A2 <10>
R BK
<14>
A1 S1 R + K5
B5
<12> <10> K5
C2+ C2- Y Y A1
A2 S2 CF2 R R
<12> 2A PS Pump
A Y
<12>
Main Drive
Crippen Created on Date
Page 1 of 1
318ti Conversion 8/15/09
Schematic Revision 3 Date
Power and Control 9/21/09

11. Project Phasing
Life Imitates Work
Phase 1 Phase 2 Phase 3
Functional EV Reliable EV Wired EV
Started Jan 09 Started May 10 ETA June 13
Complete Mar 10 Complete Aug 10 Ongoing
Drivetrain & Safety Power Steering, Interior, Complete Data Logging, WiFi
Systems complete Clutch, Heater, Detail job, dump to web, EV sensitive
Basic Data Logging navigation, Touchscreen dash
“Der Weg is das Ziel”

12. Agenda
Welcome & Introduction
Buy vs. Build Options
Common Myths and Misconceptions
Learning to Live with Range Anxiety
Potential Roadblocks to mass Adoption
1

13. Terminology
Hybrid Electric Vehicle (HEV) Prius, Insight, Escalade(?)
Plug-in Hybrid (PHEV) Chevy Volt, Modified Prius
Electric Vehicle (EV) Nissan Leaf, BMW ActiveE
Plug-in Electric Vehicle (PEV)
Battery Electric Vehicle (BEV)

14. Common EV Myths
“EVs don’t have enough range”
Source: BMW Group EVProgram Tech Review, Nov 2010

15. Common EV Myths
“EVs create more pollution by using electricity from
coal-fired generation plants”
• It’s easier to put scrubbers on power plant smoke
stacks than to control millions of tailpipes (Only 52%
of US electricity is generated using coal)
• EVs are inherently more efficient at converting
stored energy to motion. Electric motors have
efficiencies of up to 98% while an average Internal
Combustion Engine (ICE) is only 18-20% efficient

16. Common EV Myths
“The charging infrastructure must be built before
people will adopt EVs”
• Most charging will be done at home, so a public
charging infrastructure isn’t a prerequisite.
• Public Charging would definitely help: offices, airports, malls
• EV ecosystem is rapidly ramping up infrastructure in
targeted markets

17. Common EV Myths
“The grid will crash if millions of EVs charge at once”
• Current Off-Peak grid capacity could fuel the daily
commutes of 73% of all cars on the road today.
…however…
• Some studies indicate that the modern suburban
neighborhood transformers are purposefully
undersized…
• Ongoing updates to the grid metering will allow
management of charging patterns to suit local
infrastructure needs
• “Rolling UPS” concept for EVs actually uses a
charged EV to help stabilize the grid through
momentary disruptions!

18. Common EV Myths
“Battery packs don’t last long enough and are
expensive to replace”
• Advanced Battery Management Systems minimize
damage from extreme use events
• Improvements in Li-Ion production techniques and
chemistry increase production yield and reliability
• Today’s Lead-Acid battery ecosystem recycles 97%
of material in the automotive fleet’s batteries. Similar
reprocessing techniques are in development for
advanced chemistries
• EVs place extreme performance demands on
batteries. A secondary market is developing for
“retired” battery packs with less severe requirements
(UPS, Grid Stabilization)

19. Agenda
Welcome & Introduction
Buy vs. Build Options
Common Myths and Misconceptions
Learning to Live with Range Anxiety
Potential Roadblocks to mass Adoption
1

20. Where do they use PEVs?
Indoor GoKart track
Rogers AR
LAX

21. What about daily life?
• My Range:
• Max: 37mi
• Target: 20mi
• My Routes:
• Home-School-Stores 15mi
Not a problem
• Home-Airport 26mi
One way, Charger
Needed
• Home-Customer 25mi
One way, Charger
Needed
• Road Trip to Red Sox
Game?
Forget it!

22. Battery Alternatives
Type Advantage Disadvantage
Lead Acid Cheap, Available Heavy, Lowest Energy Density
Flooded Cheapest Frequent Maintenance
Sealed Flooded Lower Maintenance Sensitive to abuse
Gel or AGM No Maintenance, Safe, Pricey, Shorter lifecycle if abused
Flexible Positioning
Nickel Cadmium Longer Lifecycle, Somewhat Significantly more expensive, Battery
higher energy density Management system required
Lithium Polymer Highest energy density, quick Most expensive, battery management
charging, flexible packaging system required

23. Creative Routing

24. Speed & Aerodynamic Drag
• Slower driving leads to extended range
• Drag increases at the cube of velocity

25. Agenda
Welcome & Introduction
Buy vs. Build Options
Common Myths and Misconceptions
Learning to Live with Range Anxiety
Potential Roadblocks to mass Adoption
1

26. Which Cities Have What it Takes?
Source: Rocky Mountain Institute, Project Get Ready

27. Charging Options
• Level 1: Home, Public
• 120V, 15A
• 8-12 hrs
• Opportunity Charge
• Level 2: Home, Public
• 240V, 30A
• 4-6 hrs
• Level 3: Station
• 240 or 480V 3Ph, 80A
• 30 min

28. Charging Options, A Different Approach
• Better Place
• Partnered with Renault
• Company owns Battery
• Traditional “Station”
paradigm
• Trials in
“Economic Islands”
• Hawaii
• Israel
• Denmark

29. Other Potential Hurdles
• Not enough demand for OEMs to support
• Huge transition in Mfg Asset base
• Low Consumer Awareness of benefits and ease
of transition
• Lack of Charging Infrastructure (assumed)
• Consumer focus on Upfront costs
• “Spaghetti Regulation”
• Highway taxes collected via gasoline purchase
• First-Responder concerns

30. Key Messages
Do EVs make sense for many Americans 
Will EVs be the only thing in our Garage? 
Does it feel good to drive by gas stations 
20

31. For Additional Information
• Mass Produced Vehicles
• www.Chevrolet.com/Volt
• www.nissanusa.com/leaf-electric-car/index
• www.ford.com/technology/electric/
• http://www.greencar.com/
• Conversion Projects
• www.evalbum.com
• www.diyelectriccar.com
• Conversion Equipment Suppliers
• www.evamerica.com
• www.electroauto.com
• Infrastructure
• www.projectgetready.com
• www.coulombtech.com/
• My Conversion Blog
• mpkwh.blogspot.com/
25

32. Q&A
26

33. 6

34. What’s next for Personal Transport?
+ +
Battery Tech Problem? Prime Mover Problem? Vehicle Format Problem?

35. What’s next for Personal Transport?
+ +
• Rethink the System?
• Compressed Air Engine
• Nitrogen with Sterling Engine
• Mass Transit
• Whatever this thing is ->?

36. Thanks!

37. Return

39. Making Waves!
Using DC Pulses to vary Voltage
- Return
Pulse Width Modulation (PWM) uses full voltage pulses at a fixed switching frequency to create a
variable voltage in a machine (light bulb, DC motor, AC motor). The natural characteristics of the
load create a lag in reaching the pulse voltage, leading to a ramping effect. Therefore, by varying
the count of off & on pulses of fixed time, PWM changes the average voltage at the load. For DC
motors, PWM creates a specific voltage (e.g. half speed is 50% rated voltage).

40. Making Waves!
Using DC Pulses to make AC Waves
For AC motors, PWM creates a
sine wave at rated voltage and
changes the frequency to Return
control speed (e.g. half speed is
50% rated frequency). But,
PWM also has to manage the
three phases and keep them
~
M
separated by 120 . Note the
additional complexity of the
inverter bridge

41. Where does the Torque come from?
Max Torque 133 ft-lb @ 115 @ 500A , 0-
4300RPM 5000RPM
DC
Motor

42. Where does the Torque come from?
AC
Induction
Motor