OPEL KADETT COMBO CONVERTED TO FULLY ELECTRIC VEHICLE

Project by Rudolf Bosnjak.

PROTOTYPE DEVELOPMENT IN SARAJEVO, BOSNIA AND HERZEGOVINA

HAPCEV Project is focused to convert the gasoline and diesel fueled vehicles to run on clean electric power which does not  pollute the air essential for our lives.

Development of a proof-of-concept for ac electric motor, controller, battery pack and charging system with the goal of determining the feasibility of a marketable line of ELEKTROAUTO products. This project represents the most significant portion of driving by use of pure electric energy, in terms of investment, risks, challenges, and possible gains.

"NOTHING IS IMPOSSIBLE, EXCEPT THAT THE STATE OF YOUR MIND MAKES IT SO"

Tests shows that using electric car,  is six time cheaper for use and maintenance then when you use car with petrol or diesel engine.

Dramatic redesigns of cars will be possible when the engine compartment and the space occupied by the current driveline will no longer be necessary. Eliminating the internal combustion engine from cars will reduce vehicle pollution to ZERO.

Complete financing of this project, design and construction work on this prototype was done by Rudolf Bosnjak alone.

If, you wish to help in financing, click here.

RAZVOJ PROTOTIPA U SARAJEVU,  BOSNA I HERCEGOVINA

HAPCEV  Projekt je fokusiran da prepravi vozila sa benzinskim ili dizel motorom da rade na čistu električnu energijue bez zagađena zraka-vazduha koji trebamo za disanje. 

Razvoj i dokazivanje koncepta automobila sa naizmjeničnim električnim motorom, kontrolorom, baterijskim sistemom i načinom punjenja baterija sa ciljem testiranja pouzdanosti proizvoda i moguće prodaje ELEKTROAUTO proizvoda. Ovaj projekt predstavlja najprepoznatljiviji dio a to je vožnja automobila bez upotrebe fosilih goriva koristeći čistu električnu energiju, kroz investicije, rizik, izazove i mogući dobitak.

"NIŠTA NIJE NEMOGUĆE, OSIM DA STANJE TVOG UMA MOŽE SVE NAPRAVIT"

Testiranje je pokazalo da je električni automobil, šest puta jefitniji za korišćenje i održavanje nego automobil sa dizel motorom.

Dramatično se mjenja izgled automobila kada se izvadi benzinski ili dizel motor i izduvni sistem, rezervor za gorivo, hladnjak jer to više nije potrebno. Eliminisanjem motora sa unutrašnjim sgorijevanjem iz automobila zagadjenje zraka-vazduha se smanjuje na NULU.

Kompletno financiranje ovog projekta, dizajn, promjena konstrukcije i rad na ovom prototipu je uradio Rudolf Bosnjak sam, samcat.

Ako želite novčano pomoći u daljnjem razvoju ovog projekta klikni ovdje.

Owner: Rudolf Bosnjak
Location: Sarajevo, Bosnia and Herzegovina
Vehicle: 1988 Opel Kadett Caddy
Motor: ZK 132M 3-Phase AC, 3 PHASE MOTOR
Brand: SEVER, Subotica, Serbia.
4 Pole motor - RPM 1457
Tested with 3.000 RPM
Power: 7.5kW
Torque: 49Nm
Horse Power: 10
Drivetrain: Manual gear box with 5 speed.
Controller: Danfoss Danfoss FC 302
Danfoss FC 302 Variable Speed Drive unit, output power 11kW.
Batteries: Test done with old used batteries., 560.00 Volt, Lead-Acid, Flooded. I use 47 regular 12 volts car batteries batteries in serial connection to supply 560 DC voltage to the DC Bus capacitor into Danfoss FC-302 Variable Speed Drive unit. I can select any starting RPM for motor.
Best start is with 600 - 800 RPM gently press throttle pedal and car start in any gear you manually set.
System Voltage: 560 Volts
Seating Capacity: 2 adults

TO CONVERT ANY CAR INTO HAPCEV  ZEV - means having Zero Emission Vehicle.

MY CAR - VEHICLE DOES NOT BURN OXYGEN WE NEED FOR BREATHING.

PREPRAVKA BILO KOG VOZILA U HAPCEV  ZEV - sto znaci Nema Emisije Štetnih gasova.

MOJ AUTOMOBIL NE GORI KISIK KOJI TREBAMO ZA DISANJE

Web link to offical Danfoss information about VLT  Automation Drive which runs an Opel in Sarajevo

http://www.danfoss.com/NewsAndEvents/News/

http://forms.danfoss.com/mc/InMotion/19/R-Opel.pdf

ELEKTROAUTO WEB SERVER

Danfoss inverter pogoni Opel Kadet Combo pdf

VLT  Automation Drive runs an Opel in Sarajevo image

DONATION FROM

POKLON FIRME

http://www.danfoss.com/NewsAndEvents/News/

http://forms.danfoss.com/mc/InMotion/19/R-Opel.pdf

ELEKTROAUTO WEB SERVER

Danfoss inverter pogoni Opel Kadet Combo pdf

VLT  Automation Drive pogoni Opel u Sarajevu. slika

STOP GORENJU KISIKA NA PLANETI ZEMLJI

STOP GORENJU KISIKA U MOTORIMA SA UNUTRAŠNJIM SAGORIJEVANJEM

Reducing CO2 emissions from light-duty vehicles http://ec.europa.eu/environment/air/transport/co2/co2_home.htm

Public consultation on the implementation of the renewed strategy to reduce CO2 emissions from passenger cars and light-commercial vehicles http://ec.europa.eu/reducing_co2_emissions_from_cars/index_en.htm

STOP BURNING OXYGEN IN COMBUSTION ENGINE

STOP BURNING OXYGEN ON PLANET EARTH

A clean air supply is essential to our own health and that of the environment.  http://ec.europa.eu/environment/air/index_en.htm

Web link to: New Air Quality Directive 2008/50/EC of the European Parliament and of the Council of 21 May 2008 on ambient air quality and cleaner air for Europe. Acts adopted under the EC Treaty/Euratom Treaty whose publication is obligatory and entries into force 11.June. 2008 year.

Autor ovog projekta  STOP GORENJU KISIKA U MOTORU SA UNUTRAŠNJIM SAGORIJEVANJEM je:
Rudolf Bosnjak, Sarajevo, Bosna i Hercegovina, Evropa, planet Zemlja, galaksija Mljecni Put...

BEFORE - PRIJE

FUTURE

BUDUĆNOST

HERE IS A FULL STORY OF HOW I ACHIEVED TO ACCOMPLISH THIS ENORMOUS JOB.

OVDJE JE PRI;A KAKO SAM DOSTIGAO I URADIO OVAJ OGROMAN POSAO ZA JEDNOG COVJEKA.

MOTOR

It is comparable to the engine in a conventional car. This car OPEL COMBO CADDY has a 3 phase AC induction motor with a torque of  49 Nm at zero speed.

The motor was tested to run at a high speed of 3000 RPM. This is standard industrial 3 phase electric motor from SEVER.   When working, this motor converts the energy stored in the batteries via controller into mechanical rotation at different RPM - Revolution Per Minute.

This electric motor ensures a quick acceleration.  While braking, the motor acts like a generator (regenerative braking) and recharges the batteries.

I WAS HOPING TO RECEIVE  THE POSITIVE ANSWER FROM SEVER  CONCERNING MY REQUEST FOR COOPERATION IN RE-DESIGN OF THE MOTOR. UNFORTUNATELY, I  HAVEN'T RECEIVED AN ANSWER UNTIL NOW.

IF YOU ARE A COMPANY MANUFACTURING SIMILAR INDUSTRIAL MOTORS AND YOU ARE WILLING TO HELP BY DONATING YOUR MOTORS FOR TESTING, PLEASE CONTACT RUDOLF BOSNJAK CLICKING HERE.

MOTOR

Ima istu namjenu kao motor kod običnog autmobila. Ovaj automobil OPEL COMBO CADDY ima ugradjen  trofazni izmjenični električni motor sa silom okretanja  od 49 Nm pri početnom okretanju osovine motora.

Motor je testiran i vrti se velikom brzinom od 0 - 3000 obrtaja. Ovo je standardni industrijski trofazni motor firme SEVER.

Motar daje odlicna ubrzanja i motor se ponasa kao generator (regenerative braking) i puni baterije kada se oduzme gas ili ide nizbrdo.

NADAM SE, DA ĆE FIRMA SEVER POZITIVNO ODGOVORITI NA NEKOLIKO MOJIH ZAHTJEVA I PONUDA ZA SARADNJU U REDIZAJNU OVOG MOTORA, ZA SADA SE NE JAVLJAJU.

AKO STE FIRMA KOJA PROIZVODI SLICNE INDUSTRIJSKE ELEKTRICNE MOTORE A ZELITE DA SE VAS MOTOR UGRADJUJE U AUTOMOBILE, JAVITE SE RUDOLFU BOSNJAKU DA SE DOGOVORIMO KLIKOM OVDJE.

High security motors from SEVER

Motor I used for this project is construction has been adjusted to provisions of JUS N.S8.201. In case the motors shall meet other provisions, they are agreed with the customer. High-security motors are produced in shaft height up to 160.

The electric motor I use in this project is from manufacturer SEVER, a squirrel-cage 3-phase induction motor, totally-enclosed and cooled by external fan over the fins on the motor's case. I have to change this cooling system, because I have to add on motor shaft some additional devices. The nameplate of the motor says it is model: ZK 132M,  7.5kW, Horse Power: 10, 4 Pole motor, RPM 1457, Torque: 49 Nm.

I use this type of motor.

Model: ZK 132M

4 Pole motor - RPM 1457

Power: 7.5kW

Torgue: 49 Nm

Horse Power: 10

3 PHASE MOTOR

Motor data and comparison table HP- Horse Power and kW - kilowatts as average.

Testing how to fit standard 7.5 kW 3 phase AC electric motor to existing gear box.

Rudolf Bosnjak author of this project in front of his prototype in time of hard work on prototype.

Rudolf Bosnjak autor ovog projekta ispred svog prototipa u vrijeme intenzivnih radova i testiranja.

This is done by internal fan producing the air flow when driving. Other cooling options are also possible.

Motor ima ugradjen ventilator koji omogućava hladjenje. Hladjenje je još moguće sa protokom zraka-vazduha u vožnji i još nekim drugim načinima.

The power from the motor is delivered to the gear box via special flywheel  adapter to existing gear box.

Snaga sa motora se isporučuje na mjenjać PREKO ADAPTERA ZAMAJCA NA OSOVINI MOTORA.

Na ADAPTER ZAMAJCA je sa 6 vijaka stegnut ZAMAJAC SA STAROG DIZEL MOTORA. Na zamajac je steguta stara potisna ploča sa lamelom kvačila.

SEVER ELECTRIC MOTOR - FLY WHEEL and CLUTCH

SEVER ELEKTRICNI MOTOR - ZAMAJAC I KORPA KVACILA

CLUTCH SCHEMATIC SIDE VIEW

BOČNI PRESJEK KVAČILA

ELECTRIC MOTOR - FLY WHEEL and CLUTCH ASSEMBLY FOR HYBRID VEHICLE

ELEKTRIČNI MOTOR - ZAMAJAC I KORPA KVAČILA ZA HIBRIDNA VOZILA

Special DESIGN DISTANCE PART ON ADAPTER PLATE. THIS CASE IS FOR FUTURE USE OF DUAL ELECTRIC CLUTCH SYSTEM.

DIESEL OR PETROL ENGINE WITH ADDITIONAL 3 PHASE ELECTRIC MOTOR.

Motor i mjenjac su spojeni preko specijalne DISTANCNE CELICNE ADAPTER PLOCE KOJA CE SLUZITI KAO KUCISTE DUPLOG KVACILA ZA DUPLI POGON - HIBRID POGON.

DIZEL ILI BENZIN MOTOR SA DODATKOM TROFAZNOG ELEKTRIČNOG MOTORA.

Special Steel ADAPTER PLATE, 1 cm thick is connecting the motor and existing gear box.

Motor i mjenjać su spojeni preko specijalne ČELICNE ADAPTER PLOČE debljine 1cm.

GEAR BOX IS THE SAME AS IT WAS BEFORE!

The adapter plate had to be grinded to give space for right constant velocity joint. The power from the motor is delivered to the wheels through already existing GEAR BOX, which transform rotation in different ratio to the CV (CONSTANT VELOCITY) JOINTS deliver power to the wheels, twisting and flexing like a wrist joint as the steering wheels turn and the suspension moves over bumps. They are packed with grease and covered with rubber boots

MJENJAČ BRZINA JE OSTAO ISTI KAO I PRIJE!

Snaga motora se predaje točkovima kroz postojeći MJENAĆ, koji rotaciono kretanje u različitim odnosima prenosa predaje preko HOMOKINETIČKIH ZGLOBOVA na poluosovne koje se vrte. Ta snaga se dalje prenosi na točkove. Homokinetički zglob je napunjem mašću i zastićen je gumom.

The brain of HAPCEV ZEV is Danfoss FC-302 Variable Motor Drive Speed Controller. This is a computer based system design for industrial use and this is first time that someone used  it for purpose to optimize consumption of energy from output of batteries to maximize operating range and improve performance.

Mozak HAPCEV ZEV električnog automobila je Danfoss FC-302 Promjenjiva Kontrola Brzine i Snage Obrtaja Izmjeničnog Motora.

Ovo je u osnovi komjuterski kontrolisan sistem sa svim mogućim zastitama od preopterećenja i kratkog spoja.

Danfoss FC-302   ensures perfect speed control and optimum use of electric energy from batteries. The FC-302 also maintains an electronic log of the vehicle performances, enables service personnel to run diagnostic checks on the car and to give service information on the car.

Danfoss FC-302 osigurava odličnu kontrolu brzine i štedi električnu energiju iz baterija.

FC-302 ima unutračsnji sistem zapisa svih detalja podataka u prošlosti rada kontrolora i motora. Na taj način se može vidjeti sta se dešavalo u toku rada motora.

VLT_AutomationDrive.pdf

The system computes and gives many data on display as: RPM - revolution per minute at motor shaft, HP - how many HP you have at motor shaft, AC VOLTAGE - at motor terminal connection, kW  - power which is applied to motor.

I THANK THOSE OF YOU WHO HELPED A LOT BY GIVING ME AS DONATION DANFOSS FC-302, FREQUENCY CONVERTER VARIABLE SPEED DRIVE AND DISPLAY FOR TESTING. READ HERE.

Sistem računa sve parametre i daje na displeju: Broj obrtaja motora u minuti na osovini motora u realnom vremenu, KS - koliko konjskih snaga je trenutno dato motoru na osovini motora, IN - izmjenični napon na motoru, kW  - snaga koja se daje  motoru se vidi na displeju.

MORAM SE ZAHVALITI OSOBAMA KOJE SU MI POKLONILI - DONIRALI DANFOSS FC-302 FREKFENTNI PRETVARAC ZA KONTROLU BRZINE IZMJENICNOG MOTORA  I POKLONILI MONITOR ZA TESTIRANJE.
SVE O TOME.

This regulates the flow of voltage or current information from throttle pedal push via slide potentiometer, thus transferring data to FC-302 of how much energy to give to the 3 phase AC induction motor in direct relation to pressure applied on the accelerator pedal.

I THANK  THE  DONOR OF THE OLD POTENTIOMETER.  READ HERE 

Ona reguliše protok napona i struje prema FC-302 preko kliznog potenciometra. Sve je isto kako je bilo prije.

Kad se pritisne pedala gasa motor koristi elektrićnu struju iz baterija a frekfentni pretvarač taj napon oblikuje u izmjenićni napon 380 volti,  kvadratnih impulsa i frekfencije i na taj način se mjenja broj obrtaja motora i i njegova snaga.

MORAM SE ZAHVALITI OSOBI KOJA MI JE DONIRALI STARI KLIZNI POTENCIOMETAR SVE O TOME.

HAPCEV ZEV batteries consists of  47 batteries, each is DC 12-Volts standard car lead acid battery giving total voltage of DC 564 Volts in serial connection.

I THANK  THE  DONORS OF THE OLD  BATTERIES.  READ HERE

HAPCEV ZEV baterije sadrže 47 baterije, svaka je DC 12-Volt olovna  auto baterija koje daju ukupan jednosmjerni napon od  564 volti u serijskoj vezi.

MORAM SE ZAHVALITI OSOBAMA KOJE SU MI DONIRALI STARE ALI JOS DOBRE BATERIJE ZA TESTIRANJE SVE O TOME.

I have used old batteries which I had to test to find which ones were good for my first road test drive. I use battery tester model Bosch BAT 121, which performs a fully automatic 10-second non-current loading test on maintenance-free, standard or gel batteries. BAT 121 gives totally unambiguous test results, which indicate battery voltage, starting capability and charge. I have used embedded printer in BAT 121 to print data for each battery and labeled batteries to know which are good and which are bad to be replaced.

Koristio sam stare baterije pa sam morao svaku bateriju testirati da li moze da bude koristena u ovom prvom testu voznje na baterije.

Testiranje je radjeno sa instrumentom BAT 121 koji mi je  posudila firma VESPROM.

DONATED WOODEN MATERIAL FOR BATTERY COVER READ HERE

MORAM SE ZAHVALITI NA IVERICI ZA POKOLOPAC BATERIJA SVE O TOME

Here is one of images of my MY HYBRID VERSION for my electric car,

MY prototype. I borrow 3 phase AC petrol generator who was working in driving and I fit over battery and this generator was supplying voltage to inverter and in the same time was charging batteries in driving.... It was too noise.

I just try is this possible AND IT IS. WORKING EXCELLENT.

Ovdje je jedna slika HIBRIDNE VERZIJE za moj elektricni prototip.

Posudio sam 3 fazni električni benzinski naizmjenični generator koji je radio u toku vožnje i bio ugradjen na drvenu konstrikciju iznad baterija koji je davaoa napon za inverter i istovremeno punio baterije.

Mnogo je bio bučan. Samo sam probaoa da li je moguće napravit ovakav hibrid I MOGUĆE JE. RADIO JE IZVRSNO.

With this ampere meter I can see how much current is drain from batteries with applied voltage to Danfoss FC-302 Variable Motor Drive Speed Controller. In same time instrument is used for measuring charging current for batteries with applied voltage.

I THANK THE  DONOR FOR AMPERMETER.  READ HERE

Sa ovim ampermetrom sada mogu vidjeti koliko struje vuce Danfoss FC-302 Promjenjiva Kontrola Brzine i Snage Obrtaja Izmjenicnog Motora pri datom naponu baterija. Istovremeno ovaj instrument sluzi da bi vidio kolika je struja punjenja baterija pri datom naponu.

MORAM SE ZAHVALITI OSOBI KOJA MI JE DONIRALA AMPERMETAR SVE O TOME.

DONATED TIRE AND WHEEL READ HERE

POKLONJENA
GUMA I FELGA SVE O TOME

THE FIRST  MOTOR TEST RESULTS OF THE MOTOR WITH STAR CONNECTION  USING PURE DC CONNECTION   FROM BATTERIES

In STAR connection this motor worked excellent in all 5 speeds from 0 to 1.500 RPM under load of gear box.

With this configuration car was running on test bench 60 km per hour in fifth gear.

Current around   9-10 Amps.
Power at shaft  6-7 kW, or 7-9 HP.
Motor voltage around 370-380V.
Torque adjusted to 49 Nm.

Starting speed adjusted to 0 -1500 RPM.

PRVI  TEST MOTORA U ZVJEZDA SPAJANJU MOTORA SA CISTIM ISTOSMJERNIN NAPONOM SA BATERIJA .

Sa ovom konfiguracijom motor je pokazao da moze automobil da ubrza na test valjcima do 60km na sat u petoj brzini.

Potrosnja struje oko 9-10 ampera.
Snaga na osovini 6-7 kW
Napon motora oko 370-380 Volts
Sila podesena na 49 Nm

Pocetna brzina OBRTAJA je podesena na 0 do 1500 OBRTAJA.

TEST BENCH

THE FIRST  TEST RESULTS OF THE MOTOR WITH DELTA CONNECTION   USING PURE DC CONNECTION   FROM BATTERIES

With this configuration car was running on test bench 90km per hour in fifth gear.

Current around 14 Amps.
Power at shaft   7 kW
Motor voltage around 380 Volts
Torque adjusted to 49 Nm

At the moment my starting RPM speed is adjusted from 0 to 3000 RPM.

TEST - VALJCI

PRVI  TEST U   TROKUT SPAJANJU MOTORA SA CISTIM ISTOSMJERNIN NAPONOM SA BATERIJA .

Sa ovom konfiguracijom motor je pokazao da moze automobil da ubrza na test valjcima  90km na sat u petoj brzini.

Potrosnja struje oko 14 ampera.
Snaga na osovini 7 kW.
Napon motora oko 380 Volts.
Sila podesena na 49 Nm.
Pocetna brzina OBRTAJA je podesena na 0 do 3000 OBRTAJA.

BEV 1  BOSCHNJAK  ELECTRIC  VEHICLE

OPEL KADETT model COMBO video recordings on YOUTUBE

https://youtu.be/wIXdeGVO-ns

THE FIRST ROAD TEST DRIVE WAS PERFORMED on 21^st  April 2007.

PRVA VOZNJA NA ULICI JE VOŽENA 21 Aprila 2007 godine.

Acceleration 0- 60 km per hour on flat road around 10 - 15  second.

Maximum speed is 80 km.

TEST RAOD - TESTIRANJE

Ubrzanje 0 - 60km na sat na ravnom putu oko 10 - 15 sekundi.

Maksimlna brzina je 80 km.

Goal is to reach range around  3.000 to 5.000 km minimum, with average speed 60 - 70 km per hour, while recharging  batteries while driving.  I will try to do this.

This technology was know only to Nikola Tesla and Edwin Vincent Gray.

Cilj je, da se sa jednim punjenjem baterija i dopunjavanjem istih za vrijeme vožnje, dostigne se dužna vožnje izmedju 3.000 do 5.000km sa prosječnom brzinom izmedju 60 - 80 km na sat, dok se baterije pune u vožnji. Ja ću ovo pokušati ostvariti.

Ovu tehnologiju je znao Nikola Tesla  i Edwin Vincent Gray.

Best regards

Rudolf Bosnjak

April 2006 year.

Copyright,  All rights reserved.  Rudolf Bosnjak.