Electric
aircraft project.
At the present time with the new lithium iron cobalt batters it is possible to fly two people more than one hour. Its a little expensive for the batteries but the price will come down as more companies enter the market place. In eight years it will be possible to fly four hours as new battery technology is developed. Go on youtube and type in electric car conversion kits and you will see many people converting their cars to run on batteries. Right now some people can drive 100 miles on a charge and one person can get over 200 miles out of his Porsche using Lithium ion batteries.
At the present time with the new lithium iron cobalt batters it is possible to fly two people more than one hour. Its a little expensive for the batteries but the price will come down as more companies enter the market place. In eight years it will be possible to fly four hours as new battery technology is developed. Go on youtube and type in electric car conversion kits and you will see many people converting their cars to run on batteries. Right now some people can drive 100 miles on a charge and one person can get over 200 miles out of his Porsche using Lithium ion batteries.
I want to build an experimental electric
aircraft and will need additional funding or grants to cover the cost. Anyone
interested should contact me hankkroll@gmail.com Once we
get project off the ground (literally) I will put a video on you tube and use
my company, New Wave Technology to do additional conversions. I believe this is the future. We can't wait for the car companies to get this technology to the consumers. Now is the time to get into this business.
Sikorsky has a full
sized battery powered helicopter prototype on you tube. Check it out! It uses a
US Hybrid electric motor and two Lithium battery packs weighing 700 pounds each.
This is not practical at the present time.
The
battery packs that I think will work each weigh 135 pounds for a total weight
of 270 pounds. The 110 AH at 48 volts batteries can sustain a maximum discharge
of 30 amps and 20 amps continuous. Both battery packs hooked together can
deliver a maximum of 60 amps for one minute delivering 80 HP. I believe the plane will fly strait and Your fuel costs will be zero. The new batteries last ten years so you will be able to fly free for about ten years.
Without the 150 pound gas engine and the 150 pound fuel tanks and other equipment it leaves room for the electric 97-pound motor, controller and the battery
pack. When sitting at the airport solar cells could be
used to charge the batteries.
I
recently sold my J-3 Cub so I have some money to put into the project. It has
to fly at least two hours carrying two people. The Challenger II kit aircraft empty
weight is 350 pounds and cost about $20,000.00. Two Lithium ion battery packs with
a controller cost about $20,000.00.
I
have been researching the new lithium ion batteries and electric car
conversions for some time. There is a tremendous amount .of information on the
web right now regarding electric car conversions.
PERFORMANCE:
|
||||
CHALLENGER I
|
CHALLENGER II
|
CHALLENGER I SPL
|
CHALLENGER II SPL.
|
|
VNE |
100 MPH
|
100 MPH
|
120 MPH
|
120 MPH
|
TOP LEVEL SPEED |
63 TO 90 MPH
|
75 TO 90 MPH
|
95 TO 105 MPH
|
100 MPH
|
CRUISE SPEED |
55 TO 75 MPH
|
65 TO 70 MPH
|
75 TO 90 MPH
|
85 MPH
|
STALL SPEED |
25 MPH
|
22 MPH SOLO
30 MPH DUAL |
28 MPH
|
32 MPH SOLO
37 MPH DUAL |
CLIMB RATE |
700 TO 1200 FPM
|
1200 FPM SOLO
700 FPM DUAL |
1000 TO 1400 FPM
|
1200 FPM SOLO
700 FPM DUAL |
TAKE OFF ROLL |
100 TO 200 FT
|
100 FT. SOLO
200 FT. DUAL |
100 TO 150 FT
|
125 FT. SOLO
250 FT. DUAL |
GLIDE RATIO |
10 TO 1
|
11 TO 1 SOLO
9 TO 1 DUAL |
9 TO 1
|
10 TO 1 SOLO
8 TO 1 DUAL |
SERVICE CEILING |
12,500 TO
14,500 FEET |
14,000 FT. SOLO
12,500 FT. DUAL |
14,000 FEET
|
14,000 FT. SOLO
12,500 FT. DUAL |
FUEL USED CRUSE |
1.5 TO 2.2 GPH
|
2.3 TO 4 GPH
|
2.3 TO 3 GPH
|
3.5 GPH
|
The
Challenger II kit cost
The
following e-mail illustrates the difficulties of communicating design
specifications to someone who has never flown a plane.
200 AH Lithium Iron batteries used in electric cars. $215 Need 20 of them plus the controller. 321 pounds. 20 of the 100 AH batteries weigh 161 pounds. $117 each.
200 AH Lithium Iron batteries used in electric cars. $215 Need 20 of them plus the controller. 321 pounds. 20 of the 100 AH batteries weigh 161 pounds. $117 each.
200 Ah
Click To
Enlarge
·
Item #: TS-LFP200AHA
·
Amp-Hour (Ah): 200
·
Operating Voltage: Min
2.5V Max 4.2V
·
Weight (kg): 7.3
·
Height (mm): 256.4
·
Width (mm): 360.6
·
Depth (mm): 55.5
D&D Motor Systems, Inc.
215 Park Avenue
Syracuse, NY 13204
315-701-0635
315-701-0859 FAX
www.ddmotorsystems.com
215 Park Avenue
Syracuse, NY 13204
315-701-0635
315-701-0859 FAX
www.ddmotorsystems.com
Sent: Wednesday, December
19, 2012 10:46 PM
Subject: Drive Motor Quote
Request
Referal Page: EV_Page
Company Information
Company Information
Company: New Wave Technologies Inc.
Contact: Henry Kroll - CEO
Contact: Henry Kroll - CEO
Address:
|
513 Peninsula
Avenue
|
Kenai , AK
, 99611
|
Vehicle Type: Challenger kit aircraft
No Load Weight: 350 lbs.
Full Load Weight: 1050 lbs.
Drive Wheel Diameter: 72 in.
Rolling Tire Radius: 24 in.
Differential/Transmission & Axle Type: Direct drive 3-blade carbon fiber prop.
Differential/Transmission & Axle Efficiancy: 75%
Maximum No Load Speed: 75 MPH
Maximum Full Load Speed: 100 MPH
Controller Type: Undecided
Motor Requirements
No Load Weight: 350 lbs.
Full Load Weight: 1050 lbs.
Drive Wheel Diameter: 72 in.
Rolling Tire Radius: 24 in.
Differential/Transmission & Axle Type: Direct drive 3-blade carbon fiber prop.
Differential/Transmission & Axle Efficiancy: 75%
Maximum No Load Speed: 75 MPH
Maximum Full Load Speed: 100 MPH
Controller Type: Undecided
Motor Requirements
H.P. Required: 50 hp maximum
RPM Required: 3000
Volts: 72 volts
Maximum Current: 70 Amps
Duty Cycle: 1 Hour
Quantity Per Year: 10 or less
Comments: The weight and efficiency of potassium ion lithium batteries are approaching the point where it is possible to fly two hours. 50HP on takeoff is enough power for the Challenger to get off the ground with 30 HP required for level flight.
RPM Required: 3000
Volts: 72 volts
Maximum Current: 70 Amps
Duty Cycle: 1 Hour
Quantity Per Year: 10 or less
Comments: The weight and efficiency of potassium ion lithium batteries are approaching the point where it is possible to fly two hours. 50HP on takeoff is enough power for the Challenger to get off the ground with 30 HP required for level flight.
Henry Kroll
|
|
10:43 AM (5
hours ago)
|
|
|
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Henry Kroll
|
10:43 AM (5
hours ago)
|
Loading...
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|
10:43 AM (5
hours ago)
|
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|
||||
A propellar
hub will be fixed on the motor where a three-blade ground adjustable carbon
fiber prop is mounted. The Challenger is a pusher configuration so there is no
danger of the hub coming off. As I said before we need 50 hp for takeoff and
about 30 hp for level flight. Your smaller motor is what I need the price. Just
give me a price.
One option is
two Lithium Ion 110/ah/48 volt battery packs each weighing 135 pounds put out a
maximum 30 amps each. Both will be used for takeoff for a total of 60 amps for
one minute (96 volts with bot battery packs) a continuous output of 20 amps
each (total 40 amps with both). I don't know if it will fly on 20 amps.
Greetings
Henry,
We may be able to help you out. Please let me know a few more things. We must obtain a schematic or picture of your Challenger kit aircraft design?(Without that we cannot progress.) What differential or mechanical design will you require from our motor?(Straight output keyed shaft? Length? Splined shaft?) What are the total AMP hours for your exact lithium batteries? Let me know. We look forward to working with you on all your electric motor and controller needs.
We may be able to help you out. Please let me know a few more things. We must obtain a schematic or picture of your Challenger kit aircraft design?(Without that we cannot progress.) What differential or mechanical design will you require from our motor?(Straight output keyed shaft? Length? Splined shaft?) What are the total AMP hours for your exact lithium batteries? Let me know. We look forward to working with you on all your electric motor and controller needs.
Thanks,
Mike Dieroff
D&D Motor Systems, Inc.
215 Park Avenue
Syracuse, NY 13204
315-701-0635
315-701-0859 FAX
www.ddmotorsystems.com
Sent: Wednesday, December
19, 2012 10:46 PM
Subject: Drive Motor Quote
Request
Referal Page: EV_Page
Company Information
Company Information
Company: New Wave Technologies Inc.
Contact: Henry Kroll - CEO
Contact: Henry Kroll - CEO
Address:
|
513 Peninsula
Avenue
|
Kenai , AK
, 99611
|
Vehicle Type: Challenger kit aircraft
No Load Weight: 350 lbs.
Full Load Weight: 1050 lbs.
Drive Wheel Diameter: 72 in.
Rolling Tire Radius: 24 in.
Differential/Transmission & Axle Type: Direct drive 3-blade carbon fiber prop.
Differential/Transmission & Axle Gear Ratio: 0
Differential/Transmission & Axle Efficiancy: 75%
Maximum No Load Speed: 60 MPH
Maximum Full Load Speed: 70 MPH
Minimum Vehicle Speed Up 5 % Grade: 5 MPH
Controller Type: Undecided
Motor Requirements
No Load Weight: 350 lbs.
Full Load Weight: 1050 lbs.
Drive Wheel Diameter: 72 in.
Rolling Tire Radius: 24 in.
Differential/Transmission & Axle Type: Direct drive 3-blade carbon fiber prop.
Differential/Transmission & Axle Gear Ratio: 0
Differential/Transmission & Axle Efficiancy: 75%
Maximum No Load Speed: 60 MPH
Maximum Full Load Speed: 70 MPH
Minimum Vehicle Speed Up 5 % Grade: 5 MPH
Controller Type: Undecided
Motor Requirements
H.P. Required: 50 hp maximum
RPM Required: 3000
Volts: 72 volts
Maximum Current: 70 Amps
Duty Cycle: 1 Hour
Quantity Per Year: 10 or less
Comments: The weight and efficiency of potassium ion lithium batteries are approaching the point where it is possible to fly two hours. 50HP on takeoff is enough power for the Challenger to get off the ground with 30 HP required for level flight.
Name of Picture File:
RPM Required: 3000
Volts: 72 volts
Maximum Current: 70 Amps
Duty Cycle: 1 Hour
Quantity Per Year: 10 or less
Comments: The weight and efficiency of potassium ion lithium batteries are approaching the point where it is possible to fly two hours. 50HP on takeoff is enough power for the Challenger to get off the ground with 30 HP required for level flight.
Name of Picture File:
D&D
Motors Systems - Sales
|
|
11:32 AM (4
hours ago)
|
|
|
|||
D&D
Motors Systems - Sales
|
11:32 AM (4
hours ago)
|
Loading...
|
|
|
11:32 AM (4
hours ago)
|
|||
|
||||
We
must obtain a schematic or picture of your Challenger kit aircraft design?(Without
that we cannot progress.) What differential or mechanical design will you
require from our motor?(Straight output keyed shaft? Length? Splined
shaft?)
Mike
Sent: Thursday, December
20, 2012 2:43 PM
Subject: Re: Drive Motor
Quote Request
A propellar hub will be fixed on the motor where a three-blade ground
adjustable carbon fiber prop is mounted. The Challenger is a pusher
configuration so there is no danger of the hub coming off. As I said before we
need 50 hp for takeoff and about 30 hp for level flight. Your smaller motor is
what I need the price. Just give me a price.
One option is two Lithium Ion 110/ah/48 volt battery packs each weighing
135 pounds put out a maximum 30 amps each. Both will be used for takeoff for a
total of 60 amps for one minute (96 volts with bot battery packs) a continuous
output of 20 amps each (total 40 amps with both). I don't know if it will fly
on 20 amps.
Greetings
Henry,
We may be able to help you out. Please let me know a few more things. We must obtain a schematic or picture of your Challenger kit aircraft design?(Without that we cannot progress.) What differential or mechanical design will you require from our motor?(Straight output keyed shaft? Length? Splined shaft?) What are the total AMP hours for your exact lithium batteries? Let me know. We look forward to working with you on all your electric motor and controller needs.
We may be able to help you out. Please let me know a few more things. We must obtain a schematic or picture of your Challenger kit aircraft design?(Without that we cannot progress.) What differential or mechanical design will you require from our motor?(Straight output keyed shaft? Length? Splined shaft?) What are the total AMP hours for your exact lithium batteries? Let me know. We look forward to working with you on all your electric motor and controller needs.
Thanks,
Mike Dieroff
D&D Motor Systems, Inc.
215 Park Avenue
Syracuse, NY 13204
315-701-0635
315-701-0859 FAX
www.ddmotorsystems.com
Sent: Wednesday, December
19, 2012 10:46 PM
Subject: Drive Motor Quote
Request
Referal Page: EV_Page
Company Information
Company Information
Company: New Wave Technologies Inc.
Contact: Henry Kroll - CEO
Contact: Henry Kroll - CEO
Address:
|
513
Peninsula Avenue
|
Kenai , AK
, 99611
|
Vehicle Type: Challenger kit aircraft
No Load Weight: 350 lbs.
Full Load Weight: 1050 lbs.
Drive Wheel Diameter: 72 in.
Rolling Tire Radius: 24 in.
Differential/Transmission & Axle Type: Direct drive 3-blade carbon fiber prop.
Differential/Transmission & Axle Gear Ratio: 0
Differential/Transmission & Axle Efficiancy: 75%
Maximum No Load Speed: 60 MPH
Maximum Full Load Speed: 70 MPH
Minimum Vehicle Speed Up 5 % Grade: 5 MPH
Controller Type: Undecided
Motor Requirements
No Load Weight: 350 lbs.
Full Load Weight: 1050 lbs.
Drive Wheel Diameter: 72 in.
Rolling Tire Radius: 24 in.
Differential/Transmission & Axle Type: Direct drive 3-blade carbon fiber prop.
Differential/Transmission & Axle Gear Ratio: 0
Differential/Transmission & Axle Efficiancy: 75%
Maximum No Load Speed: 60 MPH
Maximum Full Load Speed: 70 MPH
Minimum Vehicle Speed Up 5 % Grade: 5 MPH
Controller Type: Undecided
Motor Requirements
H.P. Required: 50 hp maximum
RPM Required: 3000
Volts: 72 volts
Maximum Current: 70 Amps
Duty Cycle: 1 Hour
Quantity Per Year: 10 or less
Comments: The weight and efficiency of potassium ion lithium batteries are approaching the point where it is possible to fly two hours. 50HP on takeoff is enough power for the Challenger to get off the ground with 30 HP required for level flight.
Name of Picture File:
RPM Required: 3000
Volts: 72 volts
Maximum Current: 70 Amps
Duty Cycle: 1 Hour
Quantity Per Year: 10 or less
Comments: The weight and efficiency of potassium ion lithium batteries are approaching the point where it is possible to fly two hours. 50HP on takeoff is enough power for the Challenger to get off the ground with 30 HP required for level flight.
Name of Picture File:
3 older
messages
Henry Kroll
|
|
11:58 AM (4
hours ago)
|
|
|
|||
Henry Kroll
|
11:58 AM (4
hours ago)
|
Loading...
|
|
|
11:58 AM (4
hours ago)
|
|||
|
||||
I
will adapt the keyed shaft to the prop hub. I have a metal lathe. Just send me
a price for the 50 or 70 hp motor at 140 volts and the controller.
I
can buy the blank prop hubs from any number of aircraft suppliers. I will bor
it out myself so its not a problem. The keyed shaft would be best with a bolt
tapped into the end. Being that the Challenger aircraft is a pusher
configuration the prop will not come off.
We
must obtain a schematic or picture of your Challenger kit aircraft design?(Without
that we cannot progress.) What differential or mechanical design will you
require from our motor?(Straight output keyed shaft? Length? Splined
shaft?)
Mike
Sent: Thursday, December
20, 2012 2:43 PM
Subject: Re: Drive Motor
Quote Request
A propellar hub will be fixed on the motor where a three-blade ground
adjustable carbon fiber prop is mounted. The Challenger is a pusher
configuration so there is no danger of the hub coming off. As I said before we
need 50 hp for takeoff and about 30 hp for level flight. Your smaller motor is
what I need the price. Just give me a price.
One option is two Lithium Ion 110/ah/48 volt battery packs each weighing
135 pounds put out a maximum 30 amps each. Both will be used for takeoff for a
total of 60 amps for one minute (96 volts with bot battery packs) a continuous
output of 20 amps each (total 40 amps with both). I don't know if it will fly
on 20 amps.
Greetings
Henry,
We may be able to help you out. Please let me know a few more things. We must obtain a schematic or picture of your Challenger kit aircraft design?(Without that we cannot progress.) What differential or mechanical design will you require from our motor?(Straight output keyed shaft? Length? Splined shaft?) What are the total AMP hours for your exact lithium batteries? Let me know. We look forward to working with you on all your electric motor and controller needs.
We may be able to help you out. Please let me know a few more things. We must obtain a schematic or picture of your Challenger kit aircraft design?(Without that we cannot progress.) What differential or mechanical design will you require from our motor?(Straight output keyed shaft? Length? Splined shaft?) What are the total AMP hours for your exact lithium batteries? Let me know. We look forward to working with you on all your electric motor and controller needs.
Thanks,
Mike Dieroff
D&D Motor Systems, Inc.
215 Park Avenue
Syracuse, NY 13204
315-701-0635
315-701-0859 FAX
www.ddmotorsystems.com
Sent: Wednesday, December
19, 2012 10:46 PM
Subject: Drive Motor Quote
Request
Referal Page: EV_Page
Company Information
Company Information
Company: New Wave Technologies Inc.
Contact: Henry Kroll - CEO
Contact: Henry Kroll - CEO
Address:
|
513
Peninsula Avenue
|
Kenai , AK
, 99611
|
Vehicle Type: Challenger kit aircraft
No Load Weight: 350 lbs.
Full Load Weight: 1050 lbs.
Drive Wheel Diameter: 72 in.
Rolling Tire Radius: 24 in.
Differential/Transmission & Axle Type: Direct drive 3-blade carbon fiber prop.
Differential/Transmission & Axle Gear Ratio: 0
Differential/Transmission & Axle Efficiancy: 75%
Maximum No Load Speed: 60 MPH
Maximum Full Load Speed: 70 MPH
Minimum Vehicle Speed Up 5 % Grade: 5 MPH
Controller Type: Undecided
Motor Requirements
No Load Weight: 350 lbs.
Full Load Weight: 1050 lbs.
Drive Wheel Diameter: 72 in.
Rolling Tire Radius: 24 in.
Differential/Transmission & Axle Type: Direct drive 3-blade carbon fiber prop.
Differential/Transmission & Axle Gear Ratio: 0
Differential/Transmission & Axle Efficiancy: 75%
Maximum No Load Speed: 60 MPH
Maximum Full Load Speed: 70 MPH
Minimum Vehicle Speed Up 5 % Grade: 5 MPH
Controller Type: Undecided
Motor Requirements
H.P. Required: 50 hp maximum
RPM Required: 3000
Volts: 72 volts
Maximum Current: 70 Amps
Duty Cycle: 1 Hour
Quantity Per Year: 10 or less
Comments: The weight and efficiency of potassium ion lithium batteries are approaching the point where it is possible to fly two hours. 50HP on takeoff is enough power for the Challenger to get off the ground with 30 HP required for level flight.
Name of Picture File:
RPM Required: 3000
Volts: 72 volts
Maximum Current: 70 Amps
Duty Cycle: 1 Hour
Quantity Per Year: 10 or less
Comments: The weight and efficiency of potassium ion lithium batteries are approaching the point where it is possible to fly two hours. 50HP on takeoff is enough power for the Challenger to get off the ground with 30 HP required for level flight.
Name of Picture File:
This
would be a fun project pointing the way for future technology development.
Below is a picture of my old plane.
Another e-mail to R& D.
|  12:20 PM (42 minutes ago) | | ||
| ||||
This is not a concrete proposal to put one of your motors in a small plane. At the present time it is the research and development stage. However, we are at a point in our battery technology where it might be possible to make a plane fly two hours.
I am merely trying to find a small lightweight electric motor about 9 or 10-inches in diameter that we can adapt to the airframe. You can go on line, type in Challenger aircraft and see many pictures of these little planes. They have sold thousands of them and they have a very good reputation.
The plane has a very low empty weight of 350 pounds and a high gross weight of 1050 pounds. The wing area is quite substantial to allow the plane to glide long distances. If the pilot got in trouble it might be possible to rig the battery pack to release it from the bottom of the plane in which the pilot could glide a long distance. With a 10 to 1 glide ratio and an altitude of 6000 feet the plane could glide ten miles. Given a thermal updraft it might be possible to stay up indefinitely.
None of this should be your concern. Let my team do the research and development. All we want from you is a price of a DC motor that can put out 30 to 40 hp continuous with a peak short duration hp of around 75 hp for a couple minutes for takeoff. There are several other motors on the market that can be adapted for this.
If you are curious about what is happening in the electric aircraft field go on youtube and type in Sikorski electric powered helicopter. They are using the US Hybrid motor. I have the specifications on their "HPM450". It has a large diameter for use to drive wheels. I also have some info on other motors but haven't decided which type to use. I will also check out Boeing Surplus to see what kind of DC starter motors they have.
Also, there is a production LSA (light sport aircraft) going on the market soon and several in the experimental stage. Attached is a picture of the Challenger. You can get more info from their web site if you want to do this project yourself. I won't object. I just want a flying electric plane. If it turns out that others want to duplicate this, fine. Maybe there will be a dollar in this some place if I get to help out.
I am 69 and have a couple thousand hours in light aircraft and quite a bit of experience rebuilding them.
On Fri, Dec 21, 2012 at 4:53 AM, D&D Motors Systems - Sales <sales@ddmotorsystems.com> wrote:
KAYLOR
MOTOR
Contact: Roy Kaylor
Title: President
Phone: (831)338-2200
Company: Kaylor Energy Products Fax: (831)338-2400
Address: 20,000 Big Basin Way Email:
kaylorkit@yahoo.com
Boulder
Creek, CA 95006 Web site:
www.kaylor-kit.4t.com
Roy's
1982 EV & EV-H early prototypes were acquired by Toyota Motor Corp.
Kaylor-Kit EVs (electric vehicles) go 70 city miles at 40 m.p.h. <>
Kaylor EV-Hs (hybrids) range 50-100 m.p.g., go 500 to 1,000 freeway miles at
55-65 m.p.h. on 10 gallons of fuel, a 12-20 horsepower auxiliary gas or diesel
engine driving two generators charges 12 batteries powering a compact electric
motor.
Proven
technology at an affordable price
This
electric car conversion kit is for VW rear transaxle-based vehicles, including
Beetles and Porsche 914. It is perfect for light vehicles like VW bugs, dune
buggies or our custom fiberglass bodies on a VW chassis. The kit comes with a
powerful, peak 30 HP, shunt motor that prevents motor overspeeding including a
fully functional clutch. This lets you use a full range of gears in the
transaxle. This kit has two main assemblies: A motor/adapter plate/cooling fan
that is easily mounted to the VW transaxile with four bolts; and the second
assembly is the control board populated with heavy-duty mil spec power relays
and other control electronics.
Traction
Motor Assembly The
key to this kit is the China-2 motor and its optional 12 horsepower gas powered
auxilliary engine used to drive two generators (a military surplus 400 Amp Mil
Spec Aircraft Quality starter generator may be substituted). Because Kaylor-Kit
motors are designed to be both a starter and a generator, you can achieve
practical regenerative breaking levels that are not possible with a series motor.
The aircraft generator does this because it is a shunt motor. When stopping or
going down hill you put energy back into the batteries. Using regenerative
breaking for down hill grades also provides a huge safety advantage over cars
that have only hydraulic breaks. This is especially true when you carry the
heavy batteries used in EVs.
Aircraft
generators have another advantage because they are light. Designed to work in
an aircraft these aviation starters give you one of the best 'punch for motor
pounds' of any traction motor used today. These generators are cooled with an
external fan so even when you are lugging the motor you get maximum airflow at
all times.
Aircraft
motors have an amazing high upper RPM. At 72 volts an aircraft generator
achieves 7,200 RPM. These motors can reach 10,000 to 12,000 RPM for short
periods of time. Much of this high RPM capability comes from the Mil Spec steel
wrapped armature.
At
the heart of the kit is an elegantly engineered aluminum adapter plate (some
plates are free of manufacturers logo). This plate interfaces aircraft
propulsion technology to a rear wheel drive VW transaxile. At the center of the
adapter plate are two massive bearings that hold the center core hub. This hub
supports a lightened flywheel, pressure plate and clutch assembly. The use of a
clutch with a shunt motor allows for a smooth transition from one incremental
speed to another. Since shunt motors won't over speed and run away when running
freely the clutch also provides an additional emergency disconnect, a valuable
safety feature. For the interface to the shunt motor the adapter plate has a
standard 6-inch bolt circle and a 7/8-inch female spline.
The
Control board Assembly The
second Assembly (the control board) taps the battery and gives you two-step
voltage speed control. This gives you a high speed and a low speed for each
gear you may be in. The series of incremental speed settings gives you exactly
the same feeling as riding in a high performance gas powered sports car. Unlike
transistorized controllers, using relays with a shunt motor gives you automatic
regen without any additional hardware. Also, relays are a more forgiving
technology in case of controller failure. Transistorized controllers can rack
up over $900 in transistor replacement costs in milliseconds so they are not
used in our design. The control board consists of a main double-pole
double-throw relay. This relay gives you a two step voltage or power level for
each mechanical gear you are in. The control board also has the main
single-pole single-throw on/off power relay. Mounted on the control board is
also a heavily heat sunk charge bypass diode and the 12 volt control unit.
Ease
of assembly Both
the traction motor and control board Assemblies come ready to hook up. The only
major things you need to add are traction batteries. Batteries recommended are
6 volt, deep discharge, lead-acid golf cart batteries. At many locations in the
country you can buy used golf cart batteries at little more than their core
recycle value.
All
the components provided come complete with terminal ends that are ready to be
crimped to common '00' welding cable you can get at any welding supply store.
You need to pick the type of terminal ends for your type of battery posts. This
depends on what style battery you decide to use. All terminal ends are clearly
labeled so you can cross reference them to the system schematic provided. It is
as simple as putting tab 'A' into slot 'B'.
Relays
Verses Transistorized Control As
a professional consultant in EV propulsion for on-road, off-road, automobile,
motorcycle, race, marine, flight and aerospace applications, I have designed
many types control technologies. For the over 50 years I have worked in the EV
field.. Relays are cheaper, more reliable, easy to fix, and more efficient in
operation. A relay does not have the voltage drop that is inherent in all
semiconductor devices like a transistor. Over a decade ago a member of the
nations largest electric auto association, Bruce Mckasky, won the National Range
and endurance Rally 5 years in a row. Mackasky competed against new high-end
series motors with advanced transistorized controllers and year after year
brought them down to defeat. Each year his vehicle would beat his past record
until he finally reached a range of 127.5 miles on a single charge. Mckasky's
vehicle was a simple VW based dunebuggy powered by an aircraft generator. His
adapter plate was identical to the one included in this kit and he used the
same two-voltage step relay control scheme. The bottom line is just because
something is new, does not automatically make it better. When you consider that
some EV kits cost between $7,000 to $9,000 a classic electro mechanical system
looks pretty good.
Kit
Content Listing
Traction
Motor Assembly
- Shunt
wound traction motor.
- Shunt
motor cooling fan.
- Shunt
motor anti arch diode.
- Cooling
fan adapter and hookup hose.
- Propulsion
motor adapter plate for VW rear transaxile type vehicle.
- Adapter
plate center core hub and bearings.
- Light
weight flywheel, pressure plate and clutch disk.
- VW
gland nut with pilot shaft bearing.
Control
Plate Assembly
- Main
double throw double pole mechanically interlocked voltage stepping power
control relay.
- Single
pole single throw main on / off power relay.
- 800
Amp 50 mv shunt.
- Fined
heat sunk charge bypass diode.
- 12
Volt Control Unit. Interfaces cars existing 12 volt electrical system with
high voltage main pack power control relays.
Separately
mounted components, etc
- Main
Volt Meter.
- Main
Amp Meter.
- Main
"off-on-on" speed / voltage control switch.
- On-board
72 Volt primary and opportunity battery charger system. 120 VAC input. 72
VDC output.
- Easy
to follow electrical schematic of system.
The above youtube is a demo of a Kaylor Electric Conversion Kit
for the older VW platform. This is an older style Starter/Generator Military
Shunt DC motor with a custom made adaptor plate and flywheel from Kaylor Energy
Systems. These are no longer being made but can still be found. (Editor's note:
Roy subsequently invented the China Motor, described in this website.) This
motor can push a stock steel bodied VW Ghia to 62 mph with twelve 6 volt
batteries. It is a 72 volt system. It works perfect. Perfect for a nice fun all
electric buggy. Or Bug or Ghia.
The Kaylor motor is a 400 amp, peak 30 HP, shunt motor. At 72
volts it achieves 7,200 RPM. These motors can reach 10,000 to 12,000 RPM for short periods of time. Wt is about 60-70 lbs. It is built to military specifications. Six are currently available, plus adaptor plates, and electronics.
email akernoff2009 (@) gmail (dot) com.
Motors are @ $1,450 (reduced from @ $15,000)
Adaptor plates @ $845
| Shrink Fit Prop Hub | |
 |
Installation Instructions |
| The Shrink Fit Prop Hub is the oldest prop
hub design currently made. This hub extends out 1.5" to the face of the hub from
the engine when installed on the crankshaft. As its name implies, this is a
shrink fit hub. It has approximately a .002" to .003" interference fit on the
nose of the crankshaft. The hub is heated to about 400¼ F to install. The
Shrink Fit Prop Hub features reverse threads that sling oil back into the case
and eliminating the need for a seal. Torque to 60 ft. lbs. using Blue Locktite
after sizing the bolt. Recommended use is with standard 69mm VW crankshafts and
1/2 VW engines only. Will not fit Type 4 VW. | |
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