A2 in the AlpsAudi aluminium space frameThe motorBatteriesChargerEngine bay...Motor and controller incontroller, close upContacter boxes
OwnerSimon Kay
LocationBesozzo, Varese Italy map
Web/EmailWebPage email image
Vehicle2000 Audi A2
Standard A2, using this because of aluminum space frame (standard design weight is ~900kg)
MotorAzure Dynamics/Solectria AC24LS 3-Phase AC
ControllerAzure Dynamics/Solectria DMOC445
Batteries95 China HiPower HiPower HP- IFP 150/42/190, 3.20 Volt, Lithium-Polymer
HiPower LiFePo4's, 98 cells each 3.2V/50Ah nominal, around 300V and 15.2kWh total.
System Voltage304 Volts
ChargerChina HiPower
That supplied with batteries with specific balancing characteristics.

At the moment I have a problem with teh charger which is being resolved.
HeaterGot three 120V 400W ceramic elements from Mor Electric, part nr HFE-400-120-0-L6-WH-0 120V 400W
DC/DC ConverterIota IOTA 260VDC - 340VDC DC/DC Converter
Was thinking of skipping this - putting a solar charging system on the car instead to keep the 12V system topped up.
Decided in the end to go down the standard route.
InstrumentationXantrex Link 10
Top Speed60 MPH (96 KPH)
Guestimate, based upon Azure's graphs and the top RPM of the motor. So far I have been to 90kph.
AccelerationMaybe 17secs to 60mph fully loaded (350kg payload, call it four adults), if the Azure Dynamics modeling is right.
Range60 Miles (96 Kilometers)
This is on a normal run without totally wacking the pack.
Watt Hours/Miletoo early for this.
EV Miles
Start:70,800 Miles (113,917 Kilometers)
Current:71,000 Miles (114,239 Kilometers)
Total:200 Miles (321 Kilometers)
    As of 9/28/2009
Seating CapacityThe A2 is a roomy super mini, OK for four adults.
Curb Weight2,000 Pounds (909 Kilograms)
900kg is the target. But I think it will be the standard car weight + 50kg, even though the battery pack is 50% larger than I originally intended.
Conversion TimeUp until now - Lots of admin, emails, bureaucracy... just trying to get the gear together.

Difficult to estimate the days since I am not really working continuously, but it is not too over the top. And the 2nd one would be real quick...
Update 28/9/2009: Been working but in August I developed a charger fault. This is being resolved with a new charger from the supplier.

Update 28/6/2009: first run on the road. YESSSS. Did nearly 20km - runs fine. Now some tuning.

Update 23/6/2009: It works! Got it up and down the drive.

Update 25/5/2009: 12V main wiring is done, battery is 75% connected. Half shafts in and turning, differential has oil in it... not long until wheels roll.

Update 17/5/2009: Engine is in, controller too, the wiring is the next big job.

Update: 24/3/2009: mid January got car over here. Engine was out by Feb. Then the welder who will do the engine mount has now taken six weeks... and slowed everything up. Looking at April as the month to try and get it really together.

Update: 27/12/2008 - yes I have my registration! Just got to get the car back here...

Update: 22/12/2008 - so now I have the motor, controller, batteries and car plus various other components together. I am still awaiting the number plate. The other "problem" is everything is spread between Italy and the UK - so I hope to get the car back to Italy in Jan, and then the real work can begin.

The bureaucracy in doing this project is staggering. One day, when it is all over, I will write it up. It will suffice to say now that every effort is placed by the powers at be to stop you doing this. The technical part looks easy by comparison...

code by jerry