Transcript Electric Cars and Clean Air What a Concept!

What a Concept
Electric Cars and
Clean Air
C2EC2T
Commuter Conversion Electric Car Class for Teachers
and EV Enthusiasts
4th Annual Workshop
San Diego City High School
Coordinators: Abrán Quevedo (Mr. Q) and
Jon Karanopoulos
July 28th to August 8th, 2008
The Project
The C2EC2T workshop is a project-based
instructional offering for teachers and electric vehicle
enthusiasts. Workshop participants will learn how to
convert a small ICE (Internal Combustion Engine) car
into a NICE (No Internal Combustion Engine) car
powered by batteries. A collaborative team approach
will be used to brainstorm, plan, design, and convert
the project car within the ten-day period.
DAILY ROUTINE
PROPOSED SCHEDULE
A. Workshop will be open from 7:30 AM to 8:00 AM for coffee and
B.
C.
D.
E.
pastries. Class will start promptly at 8:00 AM each morning in the
classroom.
Mr. Q and Mr. Karanopoulos will introduce the guest speaker for the
day and the EV topic area to be covered. The presentation will take
one hour and the guest presenter will stay through the lunch period
so that individual participants may have an opportunity to ask
questions.
Immediately following the guest presentation, Mr. Q and Mr.
Karanopoulos will conduct a daily PRE-BRIEFING of activities to be
undertaken, including tools needed, work station location, and
group assignments. Participants will then go to their designated
team area to start the day’s work
At 11:30 a.m. a light (working) lunch will be provided in the
workshop and classroom area.
Work will stop at 2:30 p.m. for clean-up and DE-BRIEFING. The
purpose of the de-briefing will be to evaluate each day’s progress
and address any glitches and/or concerns.
Shop Set-up and Clean-up
Procedures
A. There will be designated areas in the shop for specific
B.
C.
D.
E.
team objectives and functions
Participants will be assigned to specific teams based on
similar skills and preference
Team leaders will be selected based on skills and
capabilities needed to meet team objectives
Final decisions related to all phases of the conversion
process and applications will be made by the C2EC2T
coordinators and team leaders
Clean-up procedures will be the responsibility of all
workshop participants and will be based on the principle
of “a place for everything and everything in its place”
Tools and Equipment
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
Car lift
Engine hoist
Hydraulic floor jack
Safety stands
Pneumatic tools and equipment
Electric saber saw
Hand tools
Welding equipment
Safety gear and apparel
Specialized electric car conversion tools,
equipment, and materials
Daily Activities Schedule
Week 1
– Day 1- The coordinators will welcome everyone and a round robin self-introduction of
workshop participants will follow. Jon Karanopoulos, San Diego High School Auto Shop teacher,
will give a tour of the auto shop. Our first presenter, Bill Hammons, President of the Electric
Vehicle Association of San Diego (EVAOSD), will deliver his presentation on EVAOSD history and
other EV organizations in the United States and the world. Mr. Hammons will also address
current EV issues related to global warming and offer a general review of the latest EV
technologies and EVents. After Mr. Hammons’ presentation, lunch will be served and ample
socializing time will be provided on our first day together. After lunch, the coordinators will
continue with orientation and distribute books, binders, workshop T-shirts, and homework
assignments. The introduction of special tools required for EV conversions and basic EV
components will follow. A safety presentation, consisting of (a) safety recommendations for EV
conversions, (b) safety procedures, and (c) safety apparel, will also be given. Shop clean up
procedures, designated team areas, selection of team leaders and members, team
brainstorming sessions will follow. Participants will then be provided an opportunity for a
hands-on activity in the use of EV car tools and components. Before leaving for the day, we all
sing “Puff the Mechanical Dragon”, our theme song.
Daily Activities Schedule
Week 1
(continued)
Tuesday – Jim Bohorquez will discuss general principles and dynamics related to a comparison of electric cars and
gas cars, with a focus on the advantages and disadvantages of both. Topic areas to be covered: wind
resistance, operating costs and environmental issues. The coordinators will then conduct a pre-briefing for
the day and assign work groups and work areas with tasks to be completed. After lunch, work will continue
until the clean-up and de-briefing period at which time book chapter assignments will be given out. We will
end by singing “Puff the Mechanical Dragon.”
Wednesday - Frank Trejo, Regional Sales Manager of Powerstride Battery. Mr. Trejos’ topic will be Deep Cycle
Batteries for EV conversions. The coordinators will then conduct a pre-briefing for the day and assign work
groups and work areas with tasks to be completed. After lunch, work will continue until the clean-up and debriefing period at which time book chapter assignments will be given out. We will end by singing “Puff the
Mechanical Dragon.”
Thursday – Russ Lemon, retired electrical engineer. Mr. Lemon’s presentation will focus on technical aspects of
electric car performance projections. The daily pre-briefing will follow after which shop participants will begin
the day’s work. The day will end with clean-up and de-briefing.
Friday – Lee Campbell, retired electrical engineer. Mr. Campbell’s topic will be EV Conversions and Solar-assists.
Mr. Campbell’s Chevy S10, which was converted two years ago, will be made available. Daily pre-briefing will
follow after which shop participants will begin the day’s work. The day will end with clean-up and debriefing.
Daily Activities Schedule
Week 2
Monday – William Rhodes, new owner of KTA Services, Inc.
KTA Services is a major player in the
provision of EV components for gas-to-electric conversions. Component parts will be presented
and current costs indicated. After the presentation, we will have the pre-briefing and get right to
work.
Tuesday –
Jason Greenblatt, M.S. in Mechanical Engineering, and an employee of San Diego Gas &
Electric. Mr. Greenblatt’s topic area will be low-rolling resistance tires for EV applications.
Following will be the daily pre-briefing, morning work, lunch break, afternoon work, debriefing
and “Puff…”
Wednesday – Dave Dahl, professional electrician.
Mr. Dahl will give a presentation on his recently
converted Chevy S10. Following will be the daily pre-briefing, morning work, lunch break,
afternoon work, debriefing, and “Puff…”
Thursday – Michael T. Kadie, EV owner.
Mr. Kadie will address kit car conversions. A kit car will be
present for viewing by workshop participants. Following will be the daily pre-briefing, morning
work, lunch break, afternoon work, debriefing, and “Puff…”
Friday – Dave Grove owner, and Bob Van Gorder conversion expert, will address classic car
conversions and present a converted 1936 RR. Dave Cutter of the Village Energy web site will be
talk about the media and how to address them regarding your future electric vehicle. Following
will be the daily pre-briefing and presenting of certificates, driving the new electric car, sharing a
final meal, followed by singing “Puff the Mechanical Dragon” one last time!
PROJECT CAR PREPARATION
A. Removal of engine, gas tank and lines, exhaust system,
B.
C.
D.
E.
radiator and hoses, and other miscellaneous ICE
components
Degrease and steam clean engine compartment and car
underbody
Brake system upgrade
Suspension system upgrade
Minor body work, preparation, and painting of project
car
Collaborative Team Area
1
Small Gauge Electrical
A. Design and draw wiring diagram and determine
B.
C.
D.
E.
component locations on project vehicle
Assemble small gauge wiring harness with connectors
and attach to major and minor components
Install gauges, wires, relays, circuit breakers, and other
electrical parts as specified by the wiring diagram
Confirm that headlights, taillights, turn signals,
windshield wipers, and other related parts are
operational
Address any additional issues regarding small gauge
wiring as necessary
Collaborative Team Area
2
Large Gauge Electrical
A. Plan and design battery pack locations and cable
B.
C.
D.
E.
placement
Hook up and test electric motor prior to attaching it to
the transmission
Test each new 12-volt battery for surface charge and
compare to specifications
Install battery box in vehicle in best possible location for
most positive and most negative terminals
Perform test and service a two-year-old battery pack
system in a similar commuter conversion car
Collaborative Team Area
3
Battery Pack Frame Fabrication/ Installation
A. Plan and design angle iron battery pack frame for front
B.
C.
D.
E.
F.
and rear locations
Fabricate plastic battery pack boxes to fit into angle iron
frames
Test chosen locations for battery pack frame on vehicle
before installation in project car
Paint frame with rust-proof primer followed by glossy
finish paint
Install battery packs in project car
Install batteries into frames and secure them
Collaborative Teams Area
4
Adaptor Plate Installation
A. Steam clean transmission housing
B. Fabricate electric motor mount per KTA instructions and
C.
D.
E.
F.
G.
illustrations and attach to existing car body bracket
Check adaptor plate for proper alignment to transmission and
electric motor
Remove flywheel ring gear and machine flywheel to reduce excess
weight
Install flywheel, clutch disc, pressure plate, and motor output shaft
coupling per specifications (magic number)
Attach motor, pressure plate, transmission, and place each onto
engine hoist
Install motor and transmission assembly into project vehicle
Collaborative Team Area
5
Low-rolling Resistance Tires
A. Locate and acquire the recommended low-rolling
B.
C.
D.
E.
resistance tires for the project vehicle
Present information and application charts on lowrolling resistance tires to workshop participants
Remove existing project car tires and install new lowrolling resistant tires
Test drive and chart low-rolling resistant tire
performance such as handling and additional range
gained
Investigate availability and cost of aluminum wheels for
the project vehicle
Collaborative Team Area
6
Power Brake
A. Preassemble power brake pump and vacuum chamber
B.
C.
D.
E.
per KTA instructions
Fabricate brackets and base as needed
Review placement of power brake pump assembly unit
with coordinator before installation
Install power brake pump assembly into project car
Test the unit and make any adjustments and/or
alterations as needed for proper operation
Collaborative Team Area
7
Reassembly of Project Car
A. Clean and reinstall floor covering and car seats; paint
B.
C.
D.
over and/or reinstall car trim
Design and install project car logos, icons, and other
final items as decided
Clean and wax exterior paint, molding, and final prep
interior
Undertake any additional detailing as needed
Collaborative Team Area
8
Workshop Documentation
A. Take and collect photographs/videos of workshop
B.
C.
D.
E.
participants during ten-day C2EC2T
Assemble a multi-media presentation of C2EC2T
workshop
Distribute workshop presentation for participant
portfolio and funding source documentation
Contact local media for possible press coverage of
C2EC2T workshop
Brainstorm preliminary ideas and location for future
C2EC2T workshops
All Team Topics
9
Related EV Topics
A. Roadside opportunity charging stations
B. Electric vehicle range extenders
C. Solar photovoltaic panels (roof racks)
D. Battery trailers
E. Regenerative braking systems
F. Amtrak city to city transportation for electric vehicles
G. Job development and future opportunities in the alternative vehicle
automotive career area
H. Entrepreneurial opportunities for electric vehicle component sales and for
the establishment of professional electric vehicle conversion shops
I. Global warming, the Greenhouse effect, the melting of polar icecaps and
Greenland ice shield at an alarming rate
J. The peaking of world oil production as of 2006 and the need to establish
alternative fuel sources
K. Any additional topic areas that may be introduced