jray3
Posts: 1671
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: Let the Hacking Begin

Wed Feb 15, 2012 11:25 am

All that unused space behind the rear inner RH quarter panel has me thinking about adding a second J1772 input. Two main reasons to do this. One: security. When opportunity charging in the wilds, one's valuable EVSE is exposed to the elements and sticky fingers. The 120VAC 8A EVSE has a skinny enough cord to set it inside the car and shut the tailgate, allowing for a bit more security, but I'm loving life with my 16A 240/120VAC universal input SPX charger, and it has a big beefy cable that won't allow the tailgate to close. So, I'd like to be able to shut the tailgate and charge in peace, with only a 120VAC extension cord poking out, and no fragile flaps open.
Secondly, an innner input port makes an easier avenue for inputting range extension amps, whether they be from a supplemental battery pack or towed genset. Who'd want to drive down the highway with an open filler flap and 6" of handle and cord sticking out the passenger side! Of course, that still doesn't answer the question of whether the onboard charger can be tricked to run while the car is underway, and also whether it will accept DC input, like the Manzanita Micro chargers can... Adding an inverter to one's range extension pack adds cost and decreases efficiency significantly.
1500 miles and counting.
2012 i-SE "MR BEAN" 110,300 miles
2016 KIA SOUL EV, 90 kW, 27 kWh, 34k miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh

jennrod12
Posts: 230
Joined: Sat Feb 11, 2012 8:51 pm
Location: Santa Clara, CA

Re: Let the Hacking Begin

Wed Feb 15, 2012 2:53 pm

Dude, you are a serious hacker! :geek:

We are going to put a stripe on our Miev, when we get it. :D

Jenn
2012 Diamond White i-MiEV ES
with green racing stripes and hubcaps (thanks to WeeJohn)
Santa Clara, CA

JoeS
Site Moderator
Posts: 3802
Joined: Thu Dec 15, 2011 5:47 am
Location: Silicon Valley, California

Re: Let the Hacking Begin

Wed Feb 15, 2012 9:54 pm

jray3, you brought up a couple of topics:

1. Great idea about having the two cables for the portable J1772 EVSE poke out the unused CHAdeMO port- this is certainly cleaner than having them dangle out an almost-closed side window. A small black plastic marine hatch might just fit on the rear inner LH quarter panel...

2. Dunno who'll stick their neck out first to feed HV dc directly into the charger (through the SPX?) :roll: I haven't looked over on the Leaf forum to see if anyone's tried it there. For myself, inefficient as it is, I'm temporarily putting together a small pack of Headways (a little under 2kWH) and a cheap inverter to carry with me for any range-stretching trips (somehow, can't see myself regressing to use my Honda EU2000i genset). Happily, we're really getting a lot of charging stations installed here in the Bay Area.
EVs: 2 Wht/Blu SE Prem., '13 Tesla MS85, 3 156v CorbinSparrows (2 Li-ion), 24v EcoScoot(LiFePO4)
EV Conv: 156v '86 Ram PU, 144v '65 Saab 96
Hybrids: 48v1kW bike
ICE: '88 Isuzu Trooper. Mothballed: '67 Saab (orig.owner), '76 MBZ L206D RHD RV

jray3
Posts: 1671
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: Let the Hacking Begin

Thu Feb 16, 2012 8:23 am

Thanks JoeS, I'd sure wanna find more data on the charger before feeding HVDC thru J1772. :twisted: I'd actually prefer to just have an Anderson connector leading straight to the pack for 330VDC import (or export), but would hafta know how that would affect the BMS. Another reason I picked the i is that my homebuilt EV's pack voltage peaks at 330V, and I've got a big UPS unit that accepts 330VDC. Wouldn't ya know that we had a 3-day power outage during my second week with the i? Sure would've been nice to tap that 16kWh onboard the i, because I wasn't taking it driving during an ice storm! My issue with a small inverter or small supplemental pack, or genset for that matter is that it's a lot of work for not much range. 1.5kW, which is about the most that could actually make it to the pack from a 120VAC source, might add a max of 5 miles of range per hour. So, one could drive a few mph faster on the highway, or avoid opportunity charging on an afternoon of errands, but not take a road trip. Especially if 'regressing' to a genset, I'd want to have about 15 kW on tap, allowing long distance highway cruising or a one-hour pit stop. I've got an old Onan Emerald genset just about ready to go as proof of concept on a trailer for my conversion. Only gonna tap it at 120V at first to go easy on the charger, but if the little calculations match reality, then it might be time to step up! I'm curious to see how much is lost to the trailer vs gained by the genny. Your little Honda inverter genset could fit nicely on a tiny platform coming out of a trailer hitch receiver. One of our SEVA members used to do that with a Sparrow! Here's my homebuilt EV weblog. http://www.karmanneclectric.blogspot.com
2012 i-SE "MR BEAN" 110,300 miles
2016 KIA SOUL EV, 90 kW, 27 kWh, 34k miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh

jray3
Posts: 1671
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: Let the Hacking Begin

Thu Feb 16, 2012 3:54 pm

Joe-n-Co.,
here's a dupe of what I just posted on the range thread.
John, thanks for such detail. Can you point to any more detail on the balancing method or hardware? In looking at range extension options, I've zeroed in on the HVDC charger output, which appears to be a quick disconnect.
Pictured http://www.caranddriver.com/photos-10q1 ... oto-335603
That may be a place to add in a pigtail for 330V input/output (no more than 10A at first, to match charger output). If a supplemental 330VDC source were plugged in there, it could be disconnected often to allow the OEM pack balancing process, and this method may not actually require any permanent modifications to the car.

Now to ID that connector and find a supplier...
2012 i-SE "MR BEAN" 110,300 miles
2016 KIA SOUL EV, 90 kW, 27 kWh, 34k miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh

jray3
Posts: 1671
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: Let the Hacking Begin

Thu Feb 16, 2012 5:50 pm

Yep, the Leaf'ers are way ahead on this. :shock: Phil of EVSEupgrade.com has built a range extension trailer powered by a 30kW Capstone microturbine on propane. He tapped into the HV pack before the DC/DC converter. Extensive thread:
http://www.mynissanleaf.com/viewtopic.p ... 4&start=50
2012 i-SE "MR BEAN" 110,300 miles
2016 KIA SOUL EV, 90 kW, 27 kWh, 34k miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh

jray3
Posts: 1671
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Range extension options

Wed Mar 14, 2012 1:58 pm

So, to supplement charge while underway, I see two basic methods: one would be to input AC through the stock charger, which could allow a conventional genset or inverter, and the other would be to input DC to the battery, either through the CHAdeMO circuit, a new direct connection, or tapping the lines between inverter and battery upstream of the current measurement device so that the main battery SOC meter remains accurate. Immediate questions that come to mind with this method are; will a boost charge reduce the allowed amount of regen, and how saggy is the traction pack under load?

I've already confirmed that a cheap genset will trip out my SPX EVSE, probably too much leakage to ground.
Anybody found what signals the car not to drive while plugged in? You can certainly drive with the charging door open!
2012 i-SE "MR BEAN" 110,300 miles
2016 KIA SOUL EV, 90 kW, 27 kWh, 34k miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh

jray3
Posts: 1671
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

Re: Let the Hacking Begin- Trailer Hitch Installation

Mon Jun 25, 2012 11:31 am

Got my 2" hitch receiver from Torklift Central. The thing is a beast- 42 lbs with all hardware included. I ordered it as raw steel and am going to do a lot of drilling to lighten it up, then they'll take it back for powdercoating. They also offer a 1 1/4" receiver, but it's mounted on the same heavy frame, so no significant weight savings. Both Torklift and a local respected welder refused to build one out of aluminum, they said that the aluminum is too soft and hardens as it flexes under load, and then it would break in dramatic fashion, rather than give some warning, as steel usually does (hmm, wonder how long it's been hanging from one side like that? :roll: ).

I also asked 'em about building a light duty steel hitch, but Class III is what they do, so it's up to me to remove weight at my own risk.
2012 i-SE "MR BEAN" 110,300 miles
2016 KIA SOUL EV, 90 kW, 27 kWh, 34k miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh

jray3
Posts: 1671
Joined: Tue Dec 06, 2011 1:05 am
Location: Tacoma area, WA
Contact: Website

DIY CHAdeMO

Mon Jun 25, 2012 11:34 am

So I chatted up the parts counter guy at my dealer, and he looked up a few things for me. Turns out they will sell the entire CHAdeMO inlet and cable assembly, but it lists at over $1400. Twice the price as the original option for an unwarranted, uninstalled add-on. That'll have to remain on the wish list for a while longer.
2012 i-SE "MR BEAN" 110,300 miles
2016 KIA SOUL EV, 90 kW, 27 kWh, 34k miles
2000 Mazda Miata EV, 78 kW, 17 kWh
1983 Grumman Kurbwatt EV,170 kW, 32 kWh
1983 Mazda RX-7 EV 43 kW 10 kWh
1971 "Karmann Eclectric" EV 240 kW 19 kWh

JoeS
Site Moderator
Posts: 3802
Joined: Thu Dec 15, 2011 5:47 am
Location: Silicon Valley, California

Re: Let the Hacking Begin

Mon Jun 25, 2012 10:31 pm

jray3, thanks for the postings. I had hoped they'd come up with an all-aluminum demountable hitch, as 42# is simply too much back there!

Good to know the CHAdeMO interface can at least be purchased.
EVs: 2 Wht/Blu SE Prem., '13 Tesla MS85, 3 156v CorbinSparrows (2 Li-ion), 24v EcoScoot(LiFePO4)
EV Conv: 156v '86 Ram PU, 144v '65 Saab 96
Hybrids: 48v1kW bike
ICE: '88 Isuzu Trooper. Mothballed: '67 Saab (orig.owner), '76 MBZ L206D RHD RV

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