Very Informative Video of BG’s C100

BG Automotive is currently manufacturing America’s first mass produced electric car, the BG C100. Here we see the first known footage of the vehicle in action. The car has extensive safety features, a steel body, and is priced under $20k. Keep in mind this car is only allowed in speed zones up to 50 mph depending on your local laws. But hell, the way things are going in Detroit, by the time these cars are ready for delivery in February 2009, they might be the only mass produced cars in America.

Awesome Video of Dodge EV smoking a Challenger

In this video from the Los Angeles Times you see the superior acceleration that comes from an electric motor. While the Challenger sports a 425 hp HEMI engine; the Dodge EV, as well as every electric car, has full torque over the entire RPM range. I always love seeing these drag races between electric drivetrain cars and internal combustion engine vehicles. While the weight of the battery back hinders EVs, you have to realize how much an electric car doesn’t need: exhaust system, intake, engine cooling system, oil, gas tank, a big heavy engine, and a complicated transmission. And an electric drivetrain uses just 12 moving parts, and efficiency at the wheels is roughly 90%. Gas engines have hundreds of moving parts that have to endure extreme heat and friction, leaving the efficiency at a measly 20%. With all the advances in electronics over the past 20 years, electric vehicles have limitless potential, while combustion vehicles have pretty much reached their peak. This drag race is a good demonstration of that fact.

The Dodge EV is part of Chrysler’s ENVI program that is currently developing three electric vehicles.

What Obama means for the Electric Car

Obama
I try not to exhibit any political bias on this site because, hey, republican, democrat, libertarian, independent, everyone likes cars. And both political frontrunners this year made strong appeals for renewable, clean energy as well as electric vehicles.

McCain stressed energy independence as a way of improving international relations, because “we need to stop buying oil from countries that don’t like us very much” (he used this argument frequently). He also threw out a proposal for a $300 million dollar government prize for whoever develops an automobile battery that far surpasses current battery technology. McCain proposed to cut ethanol subsidies, which , in my opinion, is a dead horse, and offer a $5,000 tax credit to zero-emission car buyers. Obama proposed a $7000 credit for advanced-technology vehicles, plug-ins included.

Barack Obama also shed some light on his electric automobile intentions as he cut down McCain’s battery race:

After all those years in Washington, John McCain still doesn’t get it. I commend him for his desire to accelerate the search for a battery that can power the cars of the future. I’ve been talking about this myself for the last few years. But I don’t think a $300 million prize is enough. When John F. Kennedy decided that we were going to put a man on the moon, he didn’t put a bounty out for some rocket scientist to win – he put the full resources of the United States government behind the project and called on the ingenuity and innovation of the American people. – Barack Obama, Las Vegas, June 24th, 2008.

It was a pretty close presidential race in terms of being EV friendly. But as the McCain campaign went on, things went downhill. He picked Sarah Palin, who still doesn’t believe that global warming is man made. Odd, because she vowed to solve global warming somehow, without discerning the cause. Just look at Joe Biden, a longtime champion of clean tech and climate change legislation, and compare him to her. Her slogan was “drill baby drill” while Biden wants to eliminate oil company subsidies and raise gas mileage mandates:

Take away the subsidy, which I’ve introduced legislation to do. It’s about $6 billion, $2.7 billion directly, to the oil companies, number one. Number two, investigate as the president of the US. Use the Justice Department and go in and investigate this whole issue of price gouging. Number three, though, we have to do what we all have said here, but first and foremost, significantly raise the mileage automobiles get and mandate it. – Joe Biden

Source: 2007 Dem. debate at Saint Anselm College Jun 3, 2007

Obama was not very well received when, in May, he enlightened the Detroit Auto crowd to the fact that, unless they change their ways and provide more fuel-efficient cars, they will not be able to compete with the rest of the world. Unfortunately, it may be too late for GM, as it is spiraling towards bankruptcy unless they receive a government handout. And GM doesn’t seem to want to change its ways. Obama is already stressing the importance of passing a bill that will infuse $25 billion into the big 3 automakers with stipulations that force them to invest in alternative vehicles and PHEV’s. Bailing out the big 3 could be helpful to the electric car market, as Chrysler and GM are currently developing electric cars in the Volt and ENVI programs. Saving US automakers and forcing the PHEV issue would be imperative to his plan to have 1 million PHEV on the road by 2015.

A TIME article from October 22, 2008 by Joe Klein really clarifies Obama’s intentions to build a new economy based around renewable energy development:

From Time:

[Obama] has a clearer handle on the big picture, on how various policy components fit together, and a strong sense of what his top priority would be. He wants to launch an “Apollo project” to build a new alternative-energy economy. His rationale for doing so includes some hard truths about the current economic mess: “The engine of economic growth for the past 20 years is not going to be there for the next 20. That was consumer spending. Basically, we turbocharged this economy based on cheap credit.” But the days of easy credit are over, Obama said, “because there is too much deleveraging taking place, too much debt.” A new economic turbocharger is going to have to be found, and “there is no better potential driver that pervades all aspects of our economy than a new energy economy … That’s going to be my No. 1 priority when I get into office.

Also, take into account that Obama was endorsed by Al Gore, while McCain was endorsed by George Bush and Dick Cheney. During a presidential campaign, candidates say a lot of things to appeal to a moderate public. You have to look at who endorses them and what their party stands for to get a better idea of what the candidate will actually do, once in office. The Democratic party has always been the greener party and the Obama victory is a step in the right direction for electric auto technology.

Here are some useful sites to get an idea of where Obama stands on green technology:
Clean Tech and Green Business for Obama
Obama Homepage
Popular Mechanics:McCain, Obama Promise Plug-in Cars as Detroit Charts a Timetable

What is the Tesla Roadster 1.5, exactly?

The second generation of Tesla Roadster will look exactly the same, but sport a new “Powertrain 1.5”.  This powertrain is an improved motor, inverter and gearbox designed to replace their previous two-speed transmission that had many durability, efficiency and cost challenges.  The faulty 2-speed transmission effectively forced Tesla to sell its Roadster locked into second gear, dramatically hampering acceleration. The one speed transmission “improves motor torque by a bit more than 30% beyond what was already great and the ¼ mile time for the car is now in the 12.9 second range. The top speed of the vehicle remains over 120 mph,” according to Tesla CTO JB Straubel.

According to Tesla’s site, Powertrain 1.5 makes the following improvements:

  • An improved inverter (PEM) to deliver higher motor current
  • An improved motor to handle higher current and torque
  • A new single-speed gearbox
  • A new motor to gearbox coupler and an improved motor cable
  • Upgraded vehicle firmware
  • NO changes to the battery pack

Tesla Roadster Inside

PEM-green, Battery-blue, Electric Motor-under the PEM

The Power Electronics Module (PEM) basically acts as an amplifier and guide that converts and regulates the power from the battery to the motor. When you put the pedal to the floor you tell the PEM to give the motor some juice. By using newer IGBTs (Insulated Gate Bipolar Transistors) that convert and regulate power from the battery, they have been able to boost the PEM output current by about 33% from 640A rms to 850A rms with the same number of IGBTs.  Fancy talk for using recent advances in electronic technology to make a more efficient PEM and a more powerful Roadster.

The motor has been improved by changing the casting in order to link with the new transmission. The motor terminal lugs have been changed, as well as the cable from the motor to the PEM to improve efficiency and reduce temperature rise.

The heart of the Powertrain 1.5 improvement is in the gearbox. CTO JB Straubel explains it best in his blog:

The new gearbox is the most significant change from powertrain 1.0 to 1.5. We have significantly reduced the complexity of this gearbox by getting rid of the need for shifting or speed matching between two gear sets. There is only one set of gears that is always engaged with a ratio of (8.2752:1). There are no clutches and we have also done away with the need for an electric oil pump and instead integrated a very efficient gear-driven oil pump into the gearbox. All of these simplifications have saved a great deal of mass and the new gearbox is approximately 45kg instead of 53kg for the old two-speed design.

This mass savings is even more impressive when you consider that we have designed this transmission to have a long life at a much higher input torque (400 Nm) and higher speed (14,000 rpm).

The engineering design of this new gearbox has been finished for over a month and we are now running prototypes through their paces on dynamometers. We built two initial gearboxes with machined aluminum housings so we could gain some early test results before finalizing the cast housing tooling and machining fixtures.

One of the most exciting features of this new gearbox (from an EV perspective) that we have been able to validate on the first prototypes is that it has extremely low spinning drag (less than 0.1 Nm of dry drag torque.) This is less than any other gearbox we have tested with the only possible exception being the EV1 gearbox. This low drag contributes to the 1.5 powertrain having a slightly improved range figure.

The two pictures below show some of the gears and shafts. On the left is the input shaft assembly…spinning up to 14,000 rpm bearing selection is very important. The spline on the right connects to the motor coupling. The picture on the right is the intermediate shaft assembly. Notice the transmission locking “gear” in the center that engages with a stationary pawl when the car is parked.

All these changes will dramatically improve performance without effecting the range or power draw from the battery.  Tesla has learned a lot from its inaugural launch, hopefully with this more efficient powertrain they will ramp up production.

Sources: [MotorAuthority, Tesla Motors]

Fisker Automotive helps out Michigan

Fisker KarmaFisker Automotive announced today that it is opening a new, 34,000-sq-ft Engineering and Development Center in Pontiac, Michigan. This is great news for the struggling automotive state that has a dearth of newly jobless, skilled automotive professionals. Fisker’s 34,000 square-foot location is expected to employ only around 200 workers, with 130 jobs already spoken for as of today. This announcement comes days after their legal victory over Tesla. Tesla Motors accused Fisker Automotive of stealing confidential design information and trade secrets while Fisker was contracted to help in designing Tesla’s future cars. This move to Michigan also comes not long after Tesla announced they would be closing down their Rochester Hills office near Detroit.

“The available talent, supplier base, and infrastructure in Michigan will help us reach our production goal,” said Fisker Automotive COO Bernhard Koehler. “While Fisker Automotive will continue to be headquartered in Irvine, California, the new facility will allow us the opportunity to collaborate with our Michigan supplier base and have everyone under one roof.”

The 200 engineers and designers will work on the Fisker Karma, the company’s first vehicle. The Karma is a plug-in hybrid that will travel 50 miles on electricity alone and have a maximum range of 350 miles, with a 0-60 mph time under 6 sec and and a top speed of 125 mph. The car will go on sale at the end of 2009 in North America and later in Europe. Fisker hopes to be building 15,000 cars annually by 2011. Estimated pricetag is around $80,000.

Sources: [Autoblog, Motortrend]

MINI E to use AC Propulsion Drivetrain

Autobloggreen.com had an interesting article today on another electric car that will be utilizing the AC Propulsion drivetrain that has been found in the likes of the GM EV1, Tzero, Telsa Roadster, eBox, and Venturi Fetish:

While we were discussing the upcoming premiere of the new MINI E at the LA Auto Show, we mused that the retro-cute might be sporting a drivetrain courtesy of Tesla Motors. Now comes word via Paul Scott at the new website for the film, “Revenge of the Electric Car” that the MINI will get its gumption from the good folks at AC Propulsion. This may make the MINI spiritually related to the Tesla Roadster, as it was the ACP prototype, the tzero, that served as an inspiration of sorts for the creation of the now-iconic two-seater, but, as they will share no parts, the relationship is purely metaphysical. Indeed, the only current link between ACP and Tesla is the licensing of a “reductive charging” patent.

This revelation does tell us a little something about how the MINI E will be to drive. As those who have gripped the wheel of the ACP eBox know, the re-gen effect is quite strong on this system. While it’s great for getting extra range out of the battery pack, it may take a little getting used to for some drivers. The effect is not unlike the engine braking experienced with a manually shifted car and occurs as one relieves the go-pedal of downward pressure. Once adjusted to the re-gen, the experience of motoring in the MINI E should be excellent and we look forward to being able to confirm that. For the benefit of our readers, of course.

This is exciting news, as every car utilizing this technology has been a highway capable EV, with superior performance, and range. If you’re going to put your money on an fully electric vehicle, I suggest it be one with an AC Propulsion drivetrain, based on its past history.