Posts Tagged ‘warp 9’

High Voltage Wiring

Electronics | Posted by admin June 21st, 2009

With the batteries here it’s time to start working on the high voltage wiring. Unlike the normal car power which is 12 volt and grounded to the frame, the high voltage traction power must be isolated. Because of the high amperage all of the wiring will be 2/0 electrical cable.

The first part was to map out where all the batteries are going to go and how the current will be routed. The positive ends need to be next to the negative ends so they can be easily routed with the least amount of wire. 2/0 cable is expensive stuff so measuring well will save money.

The cables all get connected with wiring lugs. These are crimped on with a special hammered crimper. You have to be carefull when you strip the ends not to cut any of the small strands that make up the cable. You also need to be carefull when putting on the lug that all of the strands fit nicely inside. A good wack on the little crimping device with a large hammer makes a good strong joint. The ends are then shrink wrapped with shrink tubing to keep out moisture.

The next step was to look closely at the wiring diagrams provided by Cafe Electric for the Zilla controller. I redrew their diagram to better fit the placement of my components in my car. This excersize also helped in my understanding of the logic and how the system would work. I am going to use two contactors. The main contactor is a Tyco Kilovac. I want to be able to go in reverse without shifting so I am using a special reversing contactor that is actually a dual contactor. This will reverse the field on the motor with the flip of a switch.

The motor goes in

Electronics | Posted by admin April 5th, 2009

The Warp 9 motor is lowered into the car for the first time.

It took taking it in and out a few times and making adjustments to the motor mount rails to get the motor perfectly lined up.

The motor is in place and lines up with the shaft.  Angle Iron is cut and drilled to bolt into the motor face.  Once the coupler arrives and everything fits, holes will be drilled and these brackets will be bolted in place.

Here the coupler is in place.

A close up of the great bracket that Lowell Simmons machined for me.  I met Lowell at the Florida EAA (Electric Auto Association) and he has been a great resource.  He teaches a shop class to some local high school kids and has them doing electric conversions on cars and even drag racing them.  One of his kids recent projects, a Porsche,  was faster off the line than a Tessla at the 2009 Battery Beach Burnout.   Its going to be interesting to see what his students end up building once they graduate.

This end  is actually my old clutch plate machined down and inserted in.  Great job.

With the coupler in place, the rest of the bracket was fabricated, painted, and bolted in place.

The wires on the motor were rigged up to test the motor.  (These will be replaced with larger cable before the car is running on full battery pack.) The motor was tested by hooking a 12 volt battery directly to the motor with the car up on jack stands.  Everything ran great and had a really cool electric whine.  Can’t wait to get the whole traction battery pack installed with the Zilla controller.

The motor mount

Restoring and Building | Posted by admin January 12th, 2009

Fabrication of the motor mount for the Warp 9 electric motor.

This mount replaces the clutch bell housing and keeps the motor in line with the drive shaft. The motor will sit in this frame and be strapped in. There is a face plate which the motor also bolts into which will be welded in place once the motor is connected to the shaft and the alignment is perfect.

The Motor

Electronics | Posted by admin November 17th, 2008

The motor for the car is a Warp 9 DC motor. At a hundred twenty five pounds this motor is a little power house.

It is a 9.25″ diameter, series wound DC motor with a double ended shaft.

Standard Features

  • 9.25” diameter, series wound DC motor
  • Weight, approx. 156 pounds
  • 32.3 HP (72 Volts, 335 Amps)*
  • 70 Ft. pounds torque*
  • 5,500 RPM’s
  • Double or single ended shafts
  • Advanced timing – factory set for CCWDE (CWDE available)
  • Industry standard mounting and bolt configuration
  • Commutators key locked onto the shaft
  • High quality, large style brushes, factory preseated over 90%
  • Exceeds Class “H” insulation
  • Drive and tail shafts keyed with pilot bearing hole
  • Delivery – from stock