Ford Ford Ranger EV Component ListRanger EV Component List

7/28/2019 Ford Ford Ranger EV Component ListRanger EV Component List

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EV CONVERSIONMAYOR COMPONENTS

AND PARTSJomel Maldonado

Adrin Bagu

Jos M. Cruz

Advisors

Awilda Melndez

Edgardo Desardn


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Donor vehicle

The proposed donor vehicle is a 2010 Ford Ranger orsimilar, with an approximate curb weight of 3120 pounds

before the conversion. A rough estimate of 500 poundswill be reduced once the internal combustion engine,radiator, fuel system, fuel tank, exhaust system andassociated parts will be removed for the conversion. Theautomatic transmission should be changed to a manualtransmission to reduce dissipation of power from theelectric motor and increase the range of miles betweencharges. The manual transmission will have the originalclutch and all 5 speeds available.


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Donor vehicle

The supplemental restraint system, air bags and AntilockBraking System will remain functional to comply with NHTSA,

DOT and other regulatory agencies. All other functions likeWipers, Horn, Seat Belts, Lights and Signals will remainoperable to comply with the DOT agency and to be certified asa road worthy vehicle. The CAN Bus communication will remainoperable, thus the instrument cluster will remain functional.Power steering and power brakes will remain as effective asthe original vehicle configuration. The total weight after theconversion is estimated to be 3800 pounds. The estimatedrange between each charge is 45 miles if driven at aconservative 40 MPH. The estimated energy consumption is385-500 watts-hour/mile.


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Manual Transmission

Since the automatic transmission dissipates a lot ofenergy in the form of friction, heat loss, rotational inertiaand viscous coupling, it will be replaced with a 5 speedmanual transmission for better drive train efficiency. Thereplaced transmission should be from a Ford Ranger witha 4 cylinder, 2.3 liter engine since it has optimal gearratios for the electric motor.


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Electric Motor

Warp 9 inch series wound DC motor, double ended shaft

Continuous Ratting = 28.8 HP / 70 lb-ft @ 72V/334.5A

Peak Ratting = 70 HP / 143 lb-ft @ 120V/435A

Max. Efficiency = 89.1


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Electric Motor


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Electric Motor


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Adapter Plate

An adapter plat will be used to couple the Warp 9 electricmotor to the manual transmission; it will retain use of theoriginal clutch. A customized aluminum coupler will matethe electric motors shaft to the manual transmission

clutch. In order to achieve reverse operation of the drivetrain, the mechanical gears will be used, thus eliminatingthe need of typical H-Bridge electrical configuration; thiswill simplify the circuit and reduce voltage drop.


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Controller

Warp P Drive controller with Pulse Width Modulation capable ofmanaging up to 1000 Amps of current at 170 volts maximuminput voltage. The approximate weight is 16 pounds.

Additional options that can be upgraded:

Cruise Control

Tachometer Input

Battery Management

Digital display output via CAN Bus communication


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Pedal Sensor

Used with the WarP-Drive Controller, Dual Hall Effect

sensors are used, to produce a signal that does notdeteriorate over time and use.

Based on the Toyota Prius Pedal sensor.


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Interface Module

Digital display connected with the controller output via CANBus communication for the following parameters:

1) Motor Amps and Volts , Battery Amps and Volts

2) Controller Temperature, Throttle Position

3) Error and warning codes

All internal sensors and displayed parameters can be saved fordata logging in a Mini SD Card.


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Traction Battery

A total of 45 Thunder Sky LiFeYPO4 Batteries will beconnected in series; each battery produces 3.2 volts andhas an amp hour capacity of 200 amps at a 20 hour

discharge rate. The total voltage will be 144 volts with anavailable power of 28.8 kW. Each battery weights 16.10pounds, which will increase the vehicles weight to anadditional 724 pounds.


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Charger

To recharge the traction batteries, a solid state 3 kW highfrequency charger will be employed. This charger has an

input of 120-230 VAC and a programmed output of 24-144VDC @ 16-80A The power factor is at 98%.


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DC-DC Converter

A solid state DC-DC converter will charge the auxiliarybattery (12 volts) with the traction batteries (144 volts). It

has an input of 100-200 VDC and an output of 14VDC @60 amps.


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Power Brake

An electric vacuum pump with a reservoir will substitutethe original vacuum source that was obtained from the

internal combustion engine. This will assure the safeoperation of the power brake system.


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Power Steering

An electric motor will drive a mechanical pump to keep

the original power steering assist of the vehicle.


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J1772 Charging Connectors

The J1772 Adapter box is used to connect a J1772

Charging Station, EVSE, to a NEMA receptacle. TheAdapter Box contains a pilot signal generator that enablesthe 220 Volts AC in the EVSE.


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Estimated Budget

Description Amount*

Components and Materials $17,200.00A or $25,800.00B

Student Wages $6,000.00

Faculty Wages $4,000.00

* Estimated amountsA Flooded Lead Acid BatteriesB Lithium-Ion Batteries


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Questions

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