Open Source Hybrid Electric Vehicle Drivetrain
Design goals
Create, and assist in productizing open designs that reduce the cost and increases ease and desirability of retrofitting older vehicles with a plug-in electric vehicle with hybrid range extender compatible with the car's existing gas tank.
This implementation will allow for the creation of a multi-fuel range extender test platform for Open Source Vehicle Experiments experiments, with easy to swap testing procedure
Key Features
- Plug-in electric drivetrain with hybrid range extender
- Run/charge efficiently on gasoline or alternative fuels from its original tank
- Run/charge from bolt on external/modular power sources (such as wood, steam, heat, hydraulic, air pressure, etc) using a standard 2" receiver
- Power external devices (via electricity, hydraulics etc)
- Create a test platform usable on its own, and compatible with Open Source Ecology's modular power sources, for testing and demonstration of alternative drive trains
- Modular open design is appropriate for an educational context in maker communities, and collaborative improvement
AI / Self driving
- We will have a prototype open source AI control system for older vehicles based open source on arduino and raspberry pi and similar equipment.
- We plan to test open source self driving using https://comma.ai/ for more modern vehicles with a can bus.
Trajectory EV
- Provided an inexpensive open electrification design that can keep classic and other common late model vehicles (such as f150 or rav4) on the road using inexpensive parts
- Trajectory is also donating an electric motor, BMS, battery system design, which they have completed for prototype phase with China batteries
- Trajectory is sourcing the initial hybrid range extender - Yonda YD23KP
Fuel2Electric
- Created a system for automating builds and matching builds to installers and advisors, and DIY kits thus productizing and simplifying the process for affordable mass conversion of older vehicles
AmpReVolt
- Created a modular battery box concept for simplifying conversions on a wide variety of vehicles (using reclaimed Tesla batteries), and is advising on the implementation of the open design
Open Source Ecology
- Seeks to develop open source HMCU Powerplant - Open Source Ecology
- Seeks to research technologies appropriate for
- Has existing modular open source power plants for farm and industrial vehicles
- Seeks to create a desirable marketing demos which will captivate social media attention and an accessible on-ramp for experimentation by the general public
- These type of modules would plug into the 2” receiver in the rear of the vehicle near the engine bay, integrate with the system by charging the batteries or in the case of the gasifier by providing fuel to a commercial range extender / generator
- Power Cube - see Genealogy
- Electric Power Cube
- Hydraulic Motor
- Steam Engine
- Open Source Fuels Construction Set
- Gasifier Burner - Open Source Ecology
- Gasifier Burner/Research Development - Open Source Ecology
Good Ancestor Foundation
- Performing the vehicle modification under a restricted grant, volunteer labor
- Cabin electrical design and layout
- Staff donating use of prototype test vehicle / platform
- Will use the vehicle, concepts and documentation in cooperation with Open Source Ecology to spread related ideas, technology and for organizational marketing
- Will use in concert with Vermont-based regenerative agriculture project for marketing purposes
Robert Roche - Media Production
- Media and videography. Location: Howland Hill Rd
Prototype Vehicle
Technical Links
1979 Type 2 / Transporter / Bus - Vin 2292077530
2.0L Fuel Injected
Service Manual
Vehicle Wiring Diagram
Starter Wiring Diagram
http://www.ratwell.com/technical/FAQ.html
Parts: www.busdepot.com(see also aircooled.net jbugs.com busboys etc)
Forums: https://www.thesamba.com/vw/
Platform choice
This vehicle platform was chosen for its iconic recognizable design, widespread use in marketing, availability of parts and documentation, simplicity of rear engine mounting for use as a test platform.
Implementation choices
Choice of China battery design or US / Used Tesla S battery design suitable for different world regions.
Prototype design 1: Based on https://www.diyelectriccar.com/threads/zilla-1k-hv-controller-with-9-advanced-dc-motor.206239/ - from Trajectory EV using China sourced LiPo batteries
- Inexpensive lithium polymer battery suitable for drivetrain and cabin load use ($5k base)
Current Design
US Production Build Kit available from Fuel2Electric based on reclaimed Tesla batteries and Netgain Hyper 9 HV:
- 1L Hybrid range extender ($3k target) YD23KP ~144V
Prep and modifications performed by volunteer parts and labor
- Upgraded to adjustable koni shocks to carry additional weight, and allow modern safer handling
- Upgraded tires to appropriate sidewall stiffness for safe handling
- Rustproofing and painting bottom ahead of battery boxes, minor welding
- Installed new fuel tank and fuel lines, fuel pump
- Removed ceiling material for running wires and partial installing of new ceiling
- Front and rear 2” receivers have been installed and purchased (for bolt on rear test platform)
- Entire bottom was coated with rustproofing material
- Dents were banged out
- Modern front seats installed for safety (from wrecked BMW 7-series)
- Sound deadening and insulation panels were installed, door seals replaced and many miscellaneous
A shop performed
- Removal of engine and re-installation of transmission in preparation for electric motor
Next steps
- Installation: Electric motor proof of operation
- Publish: design and documentation of undercarriage battery box
- Publish: electric subsystem, battery management system, range extender wiring diagrams and sketches