openinverter forum

While the components may be covered in detail in the EV conversion hardware thread in General (viewtopic.php?f=9&t=335), it would be great to get a basic list of what components are required to do an EV conversion.

There are the obvious items such as:
- Motor (standalone or as part of a transmission/gearbox)
- Transmission/gearbox (an existing one via an adaptor or re-using a reduction gear)
- Inverter (this is one of the main reasons why we've all ended up on this forum)
- Battery Management System (BMS)
- Batteries
- Charger
- Cooling system (depending on components used, but always recommended)
- Contactors/relays
- Cables, connectors, etc.
- Instruments (OEM via CAN or direct wiring, and/or 3rd party)

Other options might include
- Heat Pump
- PTC heater
- Brake booster (Vacuum pump or electrical brake booster such as the Bosch iBooster, or those made by Nissan, Toyota, etc.)
- Power Steering (electro-hydraulic?)

Tools (minimum and ideal options):
- Cable crimpers
- Insulated hand tools
- Torque wrench
- Multimeter
- Current clamp
- PC CAN interface
- PC (laptop or desktop)

The mystery starts for most people is everything required to tie all of the above together, things like:
- How to wire contactors/relays/pre-charge resistors, etc.
- What size and type of cable and connectors to use (there is plenty of math on the Internet for V vs A vs gauge, but most people don't know to look)
- What breakers/fuses/shunts are required, when and where to use them, and what ratings
- Legalities (this varies country to country, sometimes state to state, but it needs to be highlighted
- Safety (PPE, insulated tools, don't work on high voltages alone, etc.)
- Many others I can't think of...

I know this isn't necessarily the responsibility of this forum, but since part of the ethos of the Open Inverter project is to make electrification accessible, these are the kind of questions people are likely to arrive asking.

I like to think of the components sort of as the current flows i.e. working down the path from battery to motor, and then in segments. So here's how I think about it. I'm sure I'm missing something, and I am repeating a lot of what jalovick has above, but this grouping may help others

Drive
-HV Battery w/ BMS (BMS may require shunts or other harnesses)
-Fuse
-Manual Master disconnect switch
-IF RACING: safety contactor controlled by 12V switches wired in series (12V switches located on rear of car and dash)
-negative contactor (controlled by inverter)
-2 positive contactors, precharge and main (controlled by inverter)
-Inverter
-Motor
-axles and/or transmission, depending on setup

Charging (J1772)
-Aforementioned battery with BMS and fuse
-DEPENDING ON CHARGER: contactors, potentially with precharge
-charger
-J1772 port

Charging (CHADEMO)
-Aforementioned battery with BMS and fuse
-contactors
-charge controller
-shunt to measure current and voltage
-CHADEMO port

12V charging
-DC/DC converter, often (but not always) down stream of drive contactors (parallel with motor)

12V System (what connections do you need from the 12V to communicate with HV components)
-keyed 12V power (what used to go to the ICE ignition coil)
-start signal (ie what went to the ICE starter solenoid, often via neutral safety)
-brake pressure and/or brake light power
-Direction signal

Other Physical Systems/items
-cooling, inverter
-cooling, most motors (often combined with inverter)
-cooling/heating, most batteries
-brake booster or manual brake conversion
-power steering pump or manual steering conversion
-battery enclosure
-junction boxes to enclose HV connections



Tools (jalovicks list plus)
-angle grinder
-welder (or friend who can weld)
-basic geometry
-IF AMERICAN: an app to covert kW to Freedom Units (HP) so you can understand/communicate power levels


Regarding Safety (psshh where's the fun in that?)
There are three things you should never be when servicing HV components:
-tired
-in a rush
-intoxicated

Otherwise, its just a matter of common sense and being cautious.

P.S.Mangelsdorf wrote: ↑Wed Oct 21, 2020 1:42 pm -IF AMERICAN: an app to covert kW to Freedom Units (HP) so you can understand/communicate power levels

ROFL!

After I've stopped chuckling about your Freedom Units, I'd like to thank you for adding to the list. I forgot about the HV battery isolation and quite a few other bits. Thank you.

I'm sure there is more to add...