Thought I should show you all my 1964 Volkswagen Beetle which I converted to electric drive last winter.
Specifications:
Nissan Leaf EM61 motor.
Inverter with replacement controll board.
80 LEV40N cells from Mitsubishi Outlander PHEV.
SIMP-BMS from Tom de Bree talking over CANBUS with the modules.
Meanwell DC/DC converter.
Gigavac contactors for the main feed, Omrons for the charging and DC/DC feeds.
Homemade adapatorplate and coupler in aluminium and titanium.
Plans:
Because I've got a faulty inverter right now, something went wrong with the replacement board I had (not Openinverter), so plans is to put Johannes brainboard into a new inverter. Question right now is if I should go for a Gen2 inverter and use it with a Gen1 motor or should I get a new Gen1 inverter and put a adapterboard for that kind when it's avalible.
Current situation:
Right now am I trying to controll the original logic board of the Gen 1 over CAN-bus, have made it succesfully on a Gen2. Problem is the above mention broken Gen1 inverter I have at the moment. Will uppdate when I have new things to share
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Mon Aug 05, 2019 7:51 am
by mleebert
Thanks for sharing your build. I enjoyed the rear picture and seeing the motor and inverter fit in there.
Are you running a clutch?
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Mon Aug 05, 2019 7:57 am
by langoo
mleebert wrote: ↑Mon Aug 05, 2019 7:51 am
Thanks for sharing your build. I enjoyed the rear picture and seeing the motor and inverter fit in there.
Are you running a clutch?
No I'm running clutchless direct-drive have the understanding that the EV-motors in general aren't designed to have axial forces applied to their rotor which is what happens with a clutch setup.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Mon Aug 05, 2019 8:46 am
by Snufkin
langoo wrote: ↑Mon Aug 05, 2019 7:57 am
No I'm running clutchless direct-drive have the understanding that the EV-motors in general aren't designed to have axial forces applied to their rotor which is what happens with a clutch setup.
Great build!
Have you considered using Leaf motor with original Leaf diff and half-shafts (but then of course conversion from swing-axle to IRS)?
I'd like to make a Beetle conversion too, maybe some later model, but am still gathering the knowledge to decide what batteries and motor/controller to use.
langoo wrote: ↑Mon Aug 05, 2019 7:57 am
No I'm running clutchless direct-drive have the understanding that the EV-motors in general aren't designed to have axial forces applied to their rotor which is what happens with a clutch setup.
Great build!
Have you considered using Leaf motor with original Leaf diff and half-shafts (but then of course conversion from swing-axle to IRS)?
I'd like to make a Beetle conversion too, maybe some later model, but am still gathering the knowledge to decide what batteries and motor/controller to use.
No because registration gets a lot more trixie when you change more than one component on a car in Sweden. Another reason is it so that the layout of the Leaf driveunit with differential would make no sense installing in a VW though you would need to chop out the whole backseat to make it fit.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Mon Aug 05, 2019 11:41 am
by doobedoobedo
Lovely job you've done there.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Mon Aug 05, 2019 2:11 pm
by NIMMOEV
Really nice conversion, how are the Outlander batteries performing?
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Tue Aug 06, 2019 11:02 am
by langoo
Got this from Johannes yesterday and soldered it together. It's for my friends Gen2, I've also got one loose brain-board for my Gen1 laying here at home now
Yesterday did I manage to got hold of a spare Gen1 inverter, it should arrive next week from Norway.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Wed Aug 07, 2019 4:46 pm
by langoo
NIMMOEV wrote: ↑Mon Aug 05, 2019 2:11 pm
Really nice conversion, how are the Outlander batteries performing?
I've pulled 300A out of them peak and no problems what so ever yet. I'm charging them with 0,25C (10A) and balancing them with Tom91:s SimpBMS.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Sat Aug 17, 2019 9:02 pm
by Igor
Saw in Damien's thread that you've had some progress. Update please!
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Sun Aug 18, 2019 5:19 pm
by langoo
Uppdate
Some shots from todays testrun this is with CAN-controlled original Leaf logicboard in a Gen1 inverter.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Mon Aug 19, 2019 7:22 am
by Igor
Mycket bra! That looks very satisfying.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Thu Sep 05, 2019 4:36 pm
by JaniK
Are you pulling 300A from leaf inverter?
I thought it was Limited to 200A..?
Anyways, very good looking project, great to see you keeo as much stock look as possible. big thumbs up from Finland.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Thu Sep 05, 2019 5:15 pm
by langoo
JaniK wrote: ↑Thu Sep 05, 2019 4:36 pm
Are you pulling 300A from leaf inverter?
I thought it was Limited to 200A..?
Anyways, very good looking project, great to see you keeo as much stock look as possible. big thumbs up from Finland.
I'm using 80 LEV40N cells from Mitsubishi Outlander PHEV, they seems to have no problem pulling 300A in this configuration.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Fri Sep 06, 2019 8:22 am
by JaniK
Very cool so you have the 12KWh pack.
How far does the e-bubbla go per charge?
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Fri Sep 06, 2019 8:35 am
by langoo
JaniK wrote: ↑Fri Sep 06, 2019 8:22 am
Very cool so you have the 12KWh pack.
How far does the e-bubbla go per charge?
Around 70-80 km but I haven't tested it now with the CAN-BUS controlled inverter. Might be more efficient with Nissans logic board than with Paul's.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Fri Sep 06, 2019 7:30 pm
by JaniK
That's quite efficient. I have ~17kwh useable energy in my leaf and have managed 117km this summer with 88kmh on The car speedo. So your leaf-powered beetle is about the same group with wh/km as my leaf interesting, have you weighted it?
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Fri Sep 06, 2019 8:47 pm
by langoo
JaniK wrote: ↑Fri Sep 06, 2019 7:30 pm
That's quite efficient. I have ~17kwh useable energy in my leaf and have managed 117km this summer with 88kmh on The car speedo. So your leaf-powered beetle is about the same group with wh/km as my leaf interesting, have you weighted it?
940 kg dryweight
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Wed Jan 29, 2020 2:48 am
by mackoffgrid
Hi Langoo
Do you find much difference or advantages / disadvantages driving the beetle with a CAN based controller compared to the other controller. I'm not particularly worried about speed or 0-60 acceleration. For example, I'm more interested in the torque when trying to climb a curb from a stationary position.
Does the CAN/Leaf inverter limit current a bit more?
Hill Start? Creep mode possible?
Great car
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Wed Jan 29, 2020 7:07 am
by langoo
mackoffgrid wrote: ↑Wed Jan 29, 2020 2:48 am
Hi Langoo
Do you find much difference or advantages / disadvantages driving the beetle with a CAN based controller compared to the other controller. I'm not particularly worried about speed or 0-60 acceleration. For example, I'm more interested in the torque when trying to climb a curb from a stationary position.
Does the CAN/Leaf inverter limit current a bit more?
Hill Start? Creep mode possible?
Great car
I get no limitations, there is all the available torque the motor delivers in an stock Leaf, more than enough in my car. The motor feels very responsive and powerful all the time. Past 6000 rpm aren't the motor pulling harder anymore but it keeps reving gladly to 11000 rpm although not as hard.
The inverter limits the power to 80kW and aims to deliver it disregarding the battery voltage, that means that it pulls more current the lower the voltage drops.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Wed Jan 29, 2020 12:45 pm
by zippy500
I like your digital display,
How and what is it ?
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Wed Jan 29, 2020 1:05 pm
by langoo
zippy500 wrote: ↑Wed Jan 29, 2020 12:45 pm
I like your digital display,
How and what is it ?
It's just an temporary 20x4 LED connected to an Arduino Uno with a CAN-bus shield.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Wed Jan 29, 2020 9:15 pm
by mackoffgrid
Thanks Langoo
I also like your instrument display, did quick calculations on the Amps and Volts and it was around 80kW
Did you display the Amps and Volts gauge on a Raspberry Pi or Android? I couldn't see what the other gauges were.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Thu Jan 30, 2020 8:30 am
by langoo
mackoffgrid wrote: ↑Wed Jan 29, 2020 9:15 pm
Thanks Langoo
I also like your instrument display, did quick calculations on the Amps and Volts and it was around 80kW
Did you display the Amps and Volts gauge on a Raspberry Pi or Android? I couldn't see what the other gauges were.
Re: Voltswagen -64 "Leaf powered" Gen 1
Posted: Thu Jan 30, 2020 9:56 am
by mackoffgrid
Yes, Nice clean display.
I bought the 7" Pi display.
Not a RPi expert and trying to decide / figure out how to do pretty much what you're doing.
I also want to switch to Reversing camera or GPS mapping as well. Thats just switching applications.
