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Donated Vehicle: |
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The University of Kansas School of Engineering Design Project A Sustainable Approach to Automobiles and Energy Infrastructure |
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EcoHawk I and Solar Energy Filling Station
This page contains the information regarding the first sustainable vehicle built at the University of Kansas |
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Figure 1. What the car looked like when it was donated |
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Generator: |
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The Super Beetle was completely renovated and the following equipment was added. The vehicle has been tested up to 40 mph with an estimated efficiency of 80 miles per gallon equivalent and a range of 25 miles on a full battery pack. |
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Batteries: |
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Electric Motor: |
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120 VAC Battery Charger: |
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Electronic Speed Controller: |
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* battery cables sized for this potential draw |
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230 VAC Battery Charger: |
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Solar Panels #1: |
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Solar Panels #2: |
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Solar Charge Controller: |
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Solar Inverter: |
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Schüco panels connected in series (48.4 VDC, 7.45 amps), two sets of two Kyocera panels connected in series (47.2 VDC, 15.68 amps). These three strings are then connected in parallel (47.2 VDC, 23.12 amps). Four of the Discover E31A-A batteries act as the storage for solar energy (two in series, two in parallel) so if we need to swap out batteries in the Beetle, we have spares. |
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We realize we did not optimize all components from the beginning; however, because of donations and the students learning as they went, we just worried about getting it all working well. |
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Figure 2. 100% biodiesel generator in the “trunk” |
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Figure 3. Our backseat full of batteries |
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Figure 4. The prime mover of the Beetle |
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Figure 5. How we control our pride and joy |
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Figure 6. Charging from the sun |
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Figure 7. Biodiesel juicing |
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Figure 10. Free energy...well, OK maybe not completely free :) |
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Figure 11. More free energy |
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Figure 12. Controlling the sun |
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Figure 13. Plugging into the sun |
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DC-to-DC Converter |
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Figure 8. 12 VDC for lights and accessories |
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Figure 9. High efficiency LED headlights, turn-signals and tail lights |
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Note that our generator is 5 kW and the two chargers together total 4.5 kW. In addition, since our generator has both 120 VAC and 230 VAC plugs, we can actually plug both chargers in at the same time. After talking with the proper technical personnel, it is possible to drive the vehicle, turn on the generator and use both generator output plugs to charge the batteries using both chargers. |
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Figure 10. Yokohama orange oil tires |
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Item |
Description |
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Vehicle |
1974 Volkswagen Super Beetle |
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Transmission |
4-speed manual |
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Engine size |
1500 cc flat-four |
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Bore |
83 mm |
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Stroke |
69 mm |
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Compression ratio |
7.5 |
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Maximum power |
54 hp @ 4200 rpm |
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Maximum torque |
77 lb-ft @ 2600 rpm |
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Front suspension |
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Rear suspension |
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Fuel economy |
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Item |
Description |
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Fuel |
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Engine |
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Engine size |
435 cc single-cylinder |
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Bore |
86 mm |
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Stroke |
75 mm |
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Compression ratio |
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Continuous power |
8.3 hp @ 3600 rpm |
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Brake specific fuel consumption |
279 g/kW-hr |
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Rated voltage |
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Rated current |
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Max AC output |
5.5 kW |
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Item |
Description |
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Type |
Advanced Glass Mat Lead-Acid |
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Product |
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Pack voltage |
10 @ 12 VDC = 120 VDC |
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20 hr capacity |
114 amp-hr |
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Pack power |
13.68 kW-hr |
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Connectors |
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Weight |
74 lbs |
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Max charge current |
14.82 amps |
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Max discharge current |
930 amps |
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Length |
12.99 in |
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Width |
7.09 in |
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Total height |
9.29 in |
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Item |
Description |
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Type |
120 VDC Brushed Series Wound |
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Product |
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Continuous draw |
190 amps |
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1 hr draw |
225 amps |
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5 min draw |
350 amps* |
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Continuous power |
26.3 hp |
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1 hr power |
31.0 hp |
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5 min power |
48.3 hp |
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Continuous torque |
29.0 ft-lbs |
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1hr torque |
36.5 ft-lbs |
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Item |
Description |
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Type |
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Maximum input power |
1.5 kW |
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DC output voltage nominal |
120 VDC |
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DC output voltage maximum |
170 VDC |
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DC output current (115 VAC) |
9 amps |
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AC input voltage nominal |
120 VAC |
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AC input current nominal |
12 amps rms |
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AC input current maximum |
15 amps |
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Item |
Description |
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Speed controller |
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Current |
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2 min rating |
500 amps |
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5 min rating |
350 amps |
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1 hr rating |
225 amps |
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Voltage drop @ 100 amps |
0.30 volts |
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Undervolt cutback |
64 volts |
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Item |
Description |
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Type |
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Maximum input power |
3.0 kW |
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AC input voltage nominal |
230 VAC |
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AC input current maximum |
20 amps |
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Efficiency |
85% |
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DC output current |
11 amps |
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Item |
Description |
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Product |
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Type |
Polycrystalline |
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Number of panels |
2 |
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Power output |
180 W |
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Rated voltage |
24.2 VDC |
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Rated current |
7.45 amps |
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Open circuit voltage |
30.4 VDC |
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Short circuit current |
8.03 amps |
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Module efficiency |
13% |
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Item |
Description |
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Product |
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Type |
Polycrystalline |
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Number of panels |
4 |
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Power output |
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Rated voltage |
23.6 VDC |
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Rated current |
7.84 amps |
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Open circuit voltage |
29.5 VDC |
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Short circuit current |
8.35 amps |
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Module efficiency |
16+% |
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Item |
Description |
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Product |
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Nominal battery voltage |
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Maximum PV array voltage (operating) |
140 VDC |
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Maximum PV array open circuit voltage |
150 VDC |
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Array short-circuit current |
60 ADC maximum |
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Total power consumption |
2.5 W (tare) |
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Charger regulation method |
Three-stage (bulk, absorption, float) |
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Item |
Description |
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Product |
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Continuous output power |
1500 W |
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Surge power capability |
2500 W |
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DC input/operating voltage |
9.7 to 15 VDC |
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Output voltage |
120 VAC |
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Battery low voltage shutdown |
10.0 VDC |
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No load power consumption |
< 1.4 ADC |
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Full load efficiency |
90% |
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1/3 load efficiency |
95% |
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Item |
Description |
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Type |
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Nominal value |
400 W |
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Input voltage |
84-120 VDC |
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Output voltage |
13.8 VDC |
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Current limitation |
30 amps @ 12VDC |
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Nominal output current |
25 amps |
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Efficiency |
92% |