1999 Ranger Pickup

Electric Conversion

excellent, existing, environmentally  essential, electrically energy efficient,  emissions excluded,  emotionally  exciting

 

This document contains the current level of the EPT2 design.    It contains varying levels of detail. 

Many areas are still sketchy.    As the design progressed the document has been updated to reflect the changes. It shows intentions up front and historical journal at the end.   This information is offered without warrantee.

 

 The conversion of an automobile drive train is not to be undertaken lightly.  Do not attempt to replicate this project unless you know what you are doing and are willing to accept full responsibility for the outcome.

 

Although this document can be viewed as a web page, it is best viewed as a word document.

 

Contents

 

1)      Design

 

2)      Preparation of Base vehicle.

 

3)      Overall component layout.

 

4)      Mechanical assembly

 

5)      Motor Assembly Installation

 

6)      Electrical Wiring

 

7)      Electrical assembly

 

8)      Diary

 

9)      Statistics

 

10)  Credits

1)    Design Overview

Text Box: Owner Al Lococo Location Winter Haven, Fl) Web/Email Vehicle 99 Ford Ranger Extended Cab Pickup Motor Netgain Warp 9 inch Drivetrain Original 5 speed manual, Clutchless Adapter/Coupler Machinist, Wayne Alexander, EV-Blue Controller Curtis Controller 1231C-8601, 96-144VDC, 500 amps max, Throttle, 0 to 5 k/ohm input Batteries 12- 12 Volt, Universal UB4D AGM, 120 lbs., 200 AH System Voltage 144 Volts Charger Zivan NG3 charger Air Conditioner Belt driven “New” compressor Heater None DC/DC Converter Iota 30 amp, 12V Accessory battery Instrumentation Ammeter, Voltmeter Top Speed 65 MPH, guess, 59 actual so far Acceleration 0 to 40 mph,12 seconds, guess. Range 50 Miles, guess, 41 actual so far (145.7 volts residual) EV Miles Start: 105,849 Miles Current: 106,968 Miles Total: 1119 Miles As of 4/5/2008 Seating Capacity 2 adults Conversion Time 2/14/2007 –1/2/2008 11 months (includes planning). Conversion Cost $20,000 including truck ($5,300) and batteries ($3,339) Curb Weight 4,540 Pounds including truck (3,100) and batteries (1,440) Suspension/Tires Rear coil over shocks/Standard 14 inch, P205/75R14  

 

 

 

 

      

 

Requirements

 

This vehicle is configured for local driving.  Typically there will be one or two passengers with room for purchases, groceries, behind the front seat.  There are two jump seats in the back, which can hold two more passengers occasionally.   

 

The required range is 35 miles.  The vehicle will be used in Winter Haven Florida where the temperatures are moderate and the terrain is flat.  It should be capable of highway speeds (65 mph). The objective is to achieve the expected range with 40% SOC (state Of Charge) remaining.  The range of 35 miles is not expected at the maximum speed.  Normal driving will be at speeds below 45 mph, with occasional trips including short sprints of 5 or 10 miles at maximum speed.

 

The requirements are for a two-passenger vehicle with minimal cargo capacity (100 lbs.), 35-mile range, three to five year battery life, and carefree battery maintenance.  The intention is to have a car that you plug in and drive.  No need to worry about specific gravity, water levels, or how to get those low batteries back to the level of the others.

 

Design Rationale

 

The car is a conversion of a 1999 Ford Ranger Pickup Truck.  This base vehicle was chosen for ease of conversion, not because of a need for large payload utility vehicle.  The pickup truck has the ability to carry the weight of the battery pack without further modifications.  The extended cab was chosen to provide a secure area for the intended small payload.

 

Range

 

The battery pack design is based on the following rule of thumb; 20 pounds of lead battery will carry you 1 mile if the battery pack is one third of the vehicle weight.  Another rule of thumb to consider is that a vehicle consumes 4 times the power at 70 mph as it does at 35 mph.

Vehicle

my Ranger DC

ICE Wt

3440

GVWR

4760

Pack Volts

144

Unit #

12

Unit V

12

Unit Weight

120

Unit Type

UB-4D AGM

Pack Weight

1440

Saved Weight

509

Additional Weight

931

Payload

398

EV Wt

4371

Rule of Thumb Range

72

Expected Range

35

Curb/pack Ratio

3

 

 The objective is to assemble a vehicle that meets the GVWR of the Manufacturer. The initial vehicle starting weight is 3440 lbs. The completed vehicle weight is expected to be about 4370 lbs.  These tables show the details. 

 

Engine weight

350

Oil

37.5

Water

60

˝ Tank Gas

61

Exhaust etc

100

Liner, Hitch, Spare

200

Total Removed

808.5

Less Kit Weight Added

300.00

Net Weight

508.50

 

The vehicle range, based on the rule of thumb, is unrealistically high.  It is also based on exhausting the batteries to 0% State Of Charge (SOC).  The expected range takes into account the need to meet the 35 mile range objective with a 40% SOC remaining.

 

Speed

 

The remaining major design consideration is based on the tried and true typical DC conversion.  To achieve highway speeds, a Netgain 9 inch series wound motor is used with a Curtis 500 Amp controller at 144V DC. 

Netgain Warp 9 Data at 144V input

Time On

Volts

Amps

RPM