EV Independence Day, First Drive on the Streets !!

It was intended to drive the EV out of the garage for the first time under its own battery power on Independence Day, July 4, 2015.  The symbolism of Independence from Petroleum on American Independence Day was too excellent to ignore, but one week late was the best that could be done, and even then with a little improvisation as described in the previous post.

Today it finally happened!  The 1992 BMW 325i EV exited the garage and travelled its first mile on city streets under complete battery power and Soliton 1 control !!!   My son William shared the first drive with me, and the moment was sweet indeed.  It is dark now, and since the headlights apparently need some surgery, my daughter and wife will plan to share the experience tomorrow.

All is very good indeed !!

Installation of the Soliton 1 and a Control Panel

Once the batteries were installed, it felt as though all the hard work was in the rear view mirror.  It was still necessary to install the controller and the throttle, but with a little creativity, they rapidly went into the car on a temporary basis.  A flat area directly in front of the firewall on the passenger side is intended for the B+ jumper connector.  When the black plastic cover of the connector is removed (picture DSC03899), internally there are multiple terminals designed to tie together the trunk located battery, the chassis ground, and the 12+ volt power cables that are located in the hood area. 



                                 

Picture DSC0517 of the shelf at the passenger side rear of the motor compartment after the battery terminal base had been removed. (updated 8-12-2015)


                                   


Picture DSC01520 showing the platform after the tall side wall and the rear bracket had been removed with an abrasive cutting wheel.  The smaller edge lip visible in the foreground was maintained to increase the rigidity of the platform.  (updated 8-12-2015)
                                                                

Picture DSC03899 showing the connector (right side) after the plastic cover had been removed.

The connector was relocated from the top surface of the metal tray and moved underneath the metal tray.  A cardboard template was then trial fitted on the top surface.  After adjustments, the pattern was transferred to 1/2" thick plywood, and a final surface of 8.625" x 20.5" was cut.  The plywood was then notched at the outboard edge and forward corner to accommodate the plastic trim and the curvature of the adjacent metal surfaces (see picture DSC03871).  If this location is determined to be optimum and final, the plywood will later be replaced with Aluminum.

 

Picture DSC03871 showing the temporary plywood surface that was installed to support the Soliton 1 in the motor compartment.  The power and ground cables feed downward on the left and then run through the firewall. back into the cabin, and along the floor to finally reach the battery packs.

Picture DSC03876 showing one of the plastic nylon spacers (Home Depot) that was used between the plywood and the base of the Soliton 1.  These spacers provided clearance between the base of the Soliton 1 and the bolt heads visible in picture DSC03871. 

Access to allow marking the locations of the required holes for mounting the Soliton 1 was very difficult, so a sharpie and bolt were improvised to mark the required hole locations.

Picture DSC03872 showing the bolt after it was heavily marked with a Sharpie.  The Soliton 1 was then located on the predrilled plywood, the bolt was then inserted and turned with pressure so that the marked bolt tip would leave a mark on the metal surface beneath the plywood.   After the Soliton 1 and the plywood were removed, a clear round circle was evident on the metal (Picture DSC03874 with a black arrow for emphasis).

Picture DSC03874 showing one of the marked points that was then drilled to allow the bolts to pass through first a washer, the Soliton 1 base, a nylon spacer, the plywood,  the BMW metal chassis, a washer, and finally into the nut. 

Picture DSC03878 of the Soliton 1 secured to the plywood platform area.

What next remained was an installation of a throttle mechanism and control switches that would allow activation of the battery pack contactors and then application of 12+ volt power to the Soliton 1.  It was felt that to permanently connect the Soliton 1 throttle assembly to the accelerator pedal on the driver's floor would take significant effort and time, thus it was elected to make the throttle a hand activated temporary device instead.  At the right of the BMW center console area is a vertical steel structure that was used to secure the position of the console.  This steel can alternately facilitate the mounting of a 0.125"thick  Aluminum 1.5" x 1.5" x 8" angle.  The Aluminum was predrilled (d = 15/32") for three LED lighted SPST switches and  a pair of holes (d = 15/64", 3" apart) to mount the throttle (picture DSC03905).  It was also necessary to drill a lower mounting hole (picture DSC03906) in the steel structure so that the Aluminum angle would remain stationary (picture DSC03906).

Picture DSC03905 showing the predrilled front face of the mounting surface.  The top two holes were used immediately, and the lowest hole will be for future use.   The two smaller holes to the right are located to mount the throttle assembly.

Picture DSC03906 showing the side view of the mounted Aluminum angle.

Picture DSC03908 showing the installed temporary control and throttle assembly.  The top (blue LED) automotive toggle switch (Radio Shack), when illuminated, indicates that the battery pack contactors are energized and the pack voltage is being supplied to the high voltage inputs of the Soliton 1.  The green toggle switch, when illuminated, indicates that 12+ volts is being applied to the Soliton 1 IGN+ terminal, and as long as the Soliton 1 PGND terminal is grounded, the Soliton 1 controller will be activated.

The batteries were not connected to the control system until all the wiring had been checked and rechecked.  First for continuity of circuits, and then for presence of the 12+ volts under each of the toggle switches conditions.  As careful as I thought I was being, wiring mistakes were still found!!   Since no high voltage was in use during the testing, no harm, no foul, no regrets.

Back Seat Battery Tray Mounting of the Battery Safety Hardware

There is a deck area immediately adjacent to the rear bulkhead that separates the passenger compartment from the trunk, where four 0.75" openings can be found that are sealed with plastic plugs.  After the plugs are removed, these holes can be use as mounting points, and the center two could be used for the temporary placement of the trunk battery safety hardware (fuses and relays).

Picture DSC03858 of the rear deck at the front of the trunk compartment.  The potential mounting holes are in a straight line with the center pair 14.125" apart and the outer pair 24.375" apart.

The placement of the back seat battery pack also provides for an alternative mounting point of the battery safety hardware (fuses and relays).  A mounting surface can be created by attaching a pair of brackets to the side of the back seat battery tray (picture DSC03869),

Picture DSC03869 showing the brackets that were added to the back set battery tray.

Picture DSC03919 showing the two fuses (left) and two relays (right) after they were mounted to the battery tray brackets.  The battery pack outputs enter from the left and then exit to the far right.  The small gauge wires (middle right) that control the Zonka relays are connected to a terminal strip that is located at the far right of the assembly (not pictured),