On Jul 24, 2014, at 8:31 PM, Ben Apollonio <e...@bapollo.com> wrote:

> For your hybrid application, I'd go with the AC.  One word:  regen -- without 
> it to recharge the battery, "hybrid mode" is of little benefit; better to 
> just disengage the motor altogether.

I've been leaning towards AC since the beginning. I figure the biggest benefit 
from the electric motor will be with acceleration; if the electric motor does 
all that heavy lifting and then lets the V8 deal with cruising, that alone 
should be substantial. Along those lines, even if braking doesn't recover 
enough via regen to keep the batteries from emptying, an intelligent controller 
could apply minimal regen drag while cruising to provide just enough charge for 
accelerating from the next stop light -- and, again, only when the batteries 
are close to empty. And, with a *really* intelligent controller, I could punch 
in my expected trip distance, and it could adjust how much electric assist to 
give accordingly -- lots for shorter trips, less for longer ones.

> However, running slow comes at the expense of the torque multiplication in 
> your gearing; ultimately, you'll be running the motor hot in a low-efficiency 
> region.

That's what I'm gathering is the problem with direct drive -- not that the 
motors don't have enough power, but that they're not electromechanically 
efficient at low RPMs, and that translates into shorter range and more heat. 
Or, you *can* do direct drive with most any motor, but it's going to suck 
battery charge and lessen the motor's lifespan. And, conversely, dual motors 
work better in such situations because the load and head is spread between the 
two. Does efficiency go back up with dual motors, or is it just a matter of 
preventing overheating?

> As for the hybrid mode, I would strongly encourage you to take it 
> incrementally, because the controls will be a challenge and you don't want to 
> be kept off the road while you figure it out.

I think...that's an excellent suggestion. And the first hybrid mode can even be 
as simple as just turning on both systems at the same time.

> The vacuum sounds like a good idea, but my gut says you'll need inputs from 
> the throttle too.  You'll almost certainly require a control processor 
> (possibly Arduino, possibly more powerful).

Collin has pointed me to GEVCU, an Arduino-based open source vehicle control 
project. I'm thinking the second hybrid mode is the same as above, but with 
GEVCU tapped into the lines and monitoring everything. Step three is to show 
what GEVCU thinks it would do with the throttle, and step four to actually wire 
it in so it can do its thing.

> Since you're using the existing engine instead of an undersized one that 
> relies on the electric boost, and since your motor is fixed on the driveshaft 
> (meaning you can't regen without also burning energy in compression braking), 
> I think the fuel efficiency gains will be limited.  I would say you should 
> think of it more like a Honda Civic hybrid than like a Chevy Volt/Prius, 
> except it will have the ability to fully disengage the engine for EV-only 
> drive.

Actually, because of that fully electric mode, I'm expecting actual fuel 
economy to be superlative. The main battery options left on the table are 144V 
/ 10 Ah / 10C, which perfectly match the AC-51's specs with a 14.4 kWh 
capacity. The back-of-the-envelope suggests that that should be in the range of 
30 miles or so, which is going to cover most of my driving. And if I can get it 
so that the controller uses the whole battery over longer hybrid-mode trips, 
then, for example, a 60-mile trip would get at least twice the mileage with the 
system as without -- presumably, more than twice, because the electric motor 
would be doing its thing at times the V8 would otherwise be at its least 
efficient. All-day trips wouldn't see monumental efficiency gains, but I don't 
do very many of those.

b&
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