EV Components Unplugged!

EV’s have fewer parts than their gas-powered counterparts, but that doesn’t mean that they are simple. There’s a lot to learn if you want to build your own conversion. I’ve listed the basic components below, which are referenced in the photo above.

Hub Motor: This is pretty obvious- the motor drives the wheel. I’m using a QS-Motor 8kw (8000 watt) hub motor that should be good for almost 11 horsepower (compared to the stock 198cc 9.5 horsepower internal combustion engine originally supplied with the Kabine).

LiFePo4 Cell: I’m building my own battery composed of 24 LiFePo4 cells arranged in a “series” configuration. My cells should give me a range of about 40 miles at speeds of up to 55 miles per hour (90 km/h). I’m using Lishen-branded cells from China.

Battery Management System: Each cell in the battery needs to be monitored for proper charging. I’m using a Deligreen BMS. It is Bluetooth-enabled and I can monitor battery health with a smartphone app.

Controller: The controller determines how the motor behaves and operates. It can be programmed for the performance characteristics I want. Like the BMS it comes with a smartphone app.

Battery Charger: The charger takes AC (alternating current) voltage from your electrical socket, converts it to DC (Direct Current) and stores it in the cells based on the BMS parameters. I’m using a Deligreen charger that is matched to the battery cell chemistry and voltage.

Throttle: Inputs to the throttle are sent to the Controller, which activates the motor.

DC to DC Converter: This takes the 72 volt pack voltage and provides 12 volt power to operate lights, horn and other electrical devices the the car.

Other Items Not Shown: There are other electrical components; contactors, fuses, shutoffs, connectors, gauges and wires (lots of wires of different sizes and colors) . I’ll show those later as the build progresses.