Electric Porsche – Engine, Motor and Charger update

It’s here!!  Netgain Motors Warp 11HV, but before I get into that more on the other updates.

Work has moved towards getting the engine out of the ’86 ready for it’s transplant into the ’83.  This involves moving over the entire wiring harness, any sensors or brackets that are different between the two years as well as the entire intake and vacuum system.  After stripping down the “blown” engine out of the ’83 it turns out the balance shaft belt was broken, however the timing belt was intact.  Even with the extensive damage the engine isn’t actually seized, the camshaft is seized and the timing belt was strong enough to keep the engine from turning.  After sliding the timing belt off (something I’m sure isn’t supposed to be possible without loosening the tensioner) the crankshaft still turns nicely.  Both balance shafts still turn but one has slightly more “drag” than the other which could have been part of the cause.  After removing one of the motor mounts I found the hole is much larger than previous thought.

It looks like all of the parts that I need are in good shape though, and the transfer of parts has gone very smoothly, the engine will be ready to go in the ’83 fairly soon.

On the EV side though, the Warp 11 HV has arrived, and I will start the design for the coupler and adapter.  The motor is a thing of beauty and I can’t wait to start working on getting it into the ’86.

Even though the Warp 11 HV is a monster in the EV world, it’s still very compact compared to the stock 2.5L Porsche Engine.  As shown above with the Porsche engine and starter motor for scale.

I’ve also been working on the battery charger design, instead of using an off the shelf solution I’ve decided to create individual cell chargers in the form of industrial quarter brick dc/dc converters.  Each of the 90 series groups of cells will be charged by it’s own 48v to 3.3v dc/dc converter adjusted up 10% to 3.65v to charge each cell to the perfect voltage every single time.  This eliminates the need for a shunting BMS or other intrusive charging monitor.  The dc/dc converters will be in groups of 15, with these groups fed by an industrial grade 85-264v AC power supply.  By adding more of these power supplies the total charging power is scalable from 1.5kw up to 7.5kw with the existing dc/dc converters.  The charger/bms/gauges are all part of the same system and the total cost will be around $1000 instead of $1000-2000 for a charger, a few grand for a BMS and a few hundred for gauges.

All of the systems will be tied together with an Arduino Mega based microcontroller that will monitor each cells voltage, battery current, charging current, battery temperature, cabin temperature, SOC, total pack voltage, and any other systems that need control or monitoring.

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