After I blew up my Netgain Warp 11HV and Evnetics Soliton 1 controller I opted for a “safe and reliable” system in the Siemens/DMOC645 combination that were leftovers of the bankrupt Azure Dynamics transit connect project. I’ve had this in my car for years, and while it has been flawless, it’s not quite as powerful and exciting as the DC motor system that preceded it. The battery system is also a carryover, the CALB CA60’s have been fantastic however they are heavy and capacity is limited.
This is all about to change! I’ve been battery hunting for quite a while, seeing what’s available, what’s new etc. I found a deal on LG/Chevy Bolt modules from Battery Hookup: https://www.batteryhookup.com/?rfsn=4165868.2db01c These are 10S3P modules comprised of LG 60Ah pouch cells. This is 180Ah and 36v per module or roughly 6.6kwh each. I have 10 of these modules on order to create a 100S pack or 360v nominal 66kwh total battery pack. Let me remind you that the CALB pack is currently about 15kwh. Now this is fairly large, fairly heavy, and simply won’t fit in my existing battery box. The solution? To remove virtually everything in the car, motor/inverter, adapter/coupler, torque tube and transmission. Split the pack up to 6 modules front and 4 rear, plus a small Tesla drive unit in the rear. This pack is just adequate to power a small Tesla drive unit from a power perspective, but it should work pretty well with some liquid cooling on the battery modules. The overall weight of the car won’t change significantly but going from 100km to over 400km of range will be incredibly exciting.
Each module is around 70lbs, making the total pack over 700lbs. Currently I have about 450lbs of LiFePO4. This makes it seem like the car will balloon by over 250lbs, however because of the change from the Siemens/DMOC to a small Tesla drive unit, the car will lose roughly 250lbs keeping things roughly the way they are.
I have the space to use either the small front, or small rear drive unit in the 944. I technically have the space for the large rear drive unit, however the battery system isn’t capable of putting out that much power. The small drive units are capable of 220kw which is nearly 300hp and should be a welcome change to the Siemens/DMOC coming in around half of that power output.