My first EV which was call Transformer I and still driving it today had two
large batteries in it. One 300 ah 50 cell in the back and one 300 ah 40 cell
in the front.
These were like fork lift batteries. The company, Electric Fuel Propulsion
Company, base in Troy Michigan, also built the batteries for mail and fork lift
vehicles.
The motor and transmission also can be remove by dropping these units by using
a modified floor jack with supports for the motor and transmission. The motor
and transmission cross member mounts are modified so the cross member can be
unbolted and drop down.
Only have to remove the two power wires off the motor, unplug sensor wires from
the motor and shifting cable from the transmission. After the vehicle is jack
up 30 inches on heavy duty jack stands, it only takes about 65 minutes to do
this exchange.
When I visit the plant in 1976, they show me how to replace the battery packs.
You first lift the vehicle about 2 feet and place four heavy duty dolly under
the battery box which was made out of 1/4 thick aluminum weighing about 1500
lbs each.
You unplug the battery box, and remove twelve 1/2 inch bolts. Then you lift
the vehicle about 12 inches more and roll the battery box out. I then could do
the maintenance on this battery. This was normally pulling a cell out, pulling
the cell plates out of the cell box which is call a jar.
Record the specific gravity of the electrolyte and place the cells in a
container of distill water. The container is place on a table that vibrated
that removes the particles between the plates.
Test the battery for any shorts between the cells. If required, pull out a
separator and push in a new separator at the same time. Reassemble the cell,
replace the electrolyte with the same specific gravity reading that was remove,
charge the cell and the way you go for another 10 years or so.
Today, the batteries which are Li Ion - Graphite type can also be remove in
about one hour. There are three aluminum battery containers that hold 108
cells each. They are bolted down onto a plated steel plate inside a fiberglass
battery box with six 3/8 inch bolts.
To remove these batteries, the hatch cover can be lifted up to 90 degrees, and
the battery box cover can also be lifted up at 90 degrees. Two battery cables
are unbolted from the batteries and the BMS cables are unplug from the Onion
BMS control unit.
Use a modified engine hoist that uses a cable is connected to the end plates of
the batteries which has built in eye hooks for lifting the batteries out of the
EV.
Make everything maintenance ease when designing your EV.
Roland
----- Original Message -----
From: Jorg Brown via EV<mailto:[email protected]>
To: Ben Goren<mailto:[email protected]> ; Electric Vehicle Discussion
List<mailto:[email protected]>
Sent: Wednesday, March 18, 2015 12:31 AM
Subject: Re: [EVDL] Battery Swap - the stupid idea that wont die...
On Tue, Mar 17, 2015 at 7:56 PM, Ben Goren via EV
<[email protected]<mailto:[email protected]>> wrote:
> On Mar 17, 2015, at 8:44 PM, Lee Hart via EV
> <[email protected]<mailto:[email protected]>> wrote:
>
> > However, fork lift batteries cost many thousands of dollars. And they
> weigh many times more than an EV pack. And yet they *do* routinely swap
> them anyway.
>
> Yes and no.
>
> The owners of the forklifts and the batteries swap the batteries in and
> out the same way you yourself might swap the batteries on your cordless
> drill.
>
> But what the owners of the forklifts _aren't_ doing is swapping batteries
> with some other company that charges them. That's the part that doesn't
> make economic sense.
Right. With a forklift, you own 2 or 3 batteries, and you do the swap.
The only economic change is that the battery becomes slightly more valuable
as you charge it, and then less valuable as you use it (and depreciate
it). Your total economic investment isn't changing by several thousand
dollars up or down when you swap, and there's no opportunity for you to
ditch your pack onto some other poor guy because you fried it that time
when you left the forklift lights on all night.
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