Yes, plenty of progress since our last post. After a grueling Christmas/new year period constantly at it, we had to take a break from the project, recharge our energies (as-in human energies) before we could launch into the final build.
It was "fun" taking the Hydraulic Pump (that drives suspension, brakes and power steering in a Citroen DS) off the ICE and adapting it for an electric motor that now drives the Hydropneumatic system!
Well a bit of detail! We are utilising a 24v x 450w x 400 RPM bicycle motor to drive the pump (as kindly recommended by Henk the only other Citroen DS conversion I know off; in Holland). The previous motor I had acquired from China did not work as it was not geared; high-revving with no low-end torque. My friend Geoff machined pulleys for me an supplied a rubber toothed belt that now drives the pump off the motor.
Joey sample assembly
All 360 batteries that give us 240Ah @ 96v, are now assembled and mounted in the vehicle, mostly up-front on top of the motor and some in the place where the fuel tank used to reside. This gives optimal weight distribution and overall weight that matches that of the original vehicle. And what a sight it is.........
|"Petrol Tank" Batteries|
|First 2 sets of Batteries mounted|
|First 3 sets of Batteries mounted with Controller|
|Notice the redirected Gear Lever Mechanism, now underneath the Batteries|
|The (all so important) accumulator re-position from the old ICE|
|The Hall-Effect Throttle|
|Wiring the Controller and Contactor|
|Another view of the Controller|
Citroen does not use a traditional foot brake. Instead it utilises a "mushroom" similar to the old dimmer switches in old cars for those of us old enough to remember. In any case, it is a small mound on the floor that you merely squeeze millimetrically with your foot to generate amazing braking power. We have placed a hall-effect "throttle" pedal over the top of the "mushroom so that now the firs 75% of the travel is braking utilising regen to slow down the vehicle with the "mushroom" available just by moving the pedal further to activate the disk brakes for positive and aggressive braking requirements, hopefully only on rare occasions. All other times, braking is recharging the batteries.
This theory remains to be tested in practice. Now off to do some more cabling............... Stay tuned!