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Freelander 1 Freelander EV

Discussion in 'Land Rover Freelander' started by Alibro, Jun 19, 2020.

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  1. kernowsvenski

    kernowsvenski Well-Known Member

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    This is so good! I'm really very impressed @Alibro
    Such a great project and being so well executed, more strength to your elbow old chap.
     
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  2. Alibro

    Alibro Well-Known Member

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    A massive thanks to all you guys (if I missed, sorry :oops:) who have left such kind remarks.

    The thing is I could never have got this far without the help and advice of everyone here so I'm afraid you're all to blame for the endless saga of cockups, stupid questions, questionable decisions and lousy videos with incompetent commentary. :confused:

    Expect a great deal more of the same to come. :p
     
    Last edited: Apr 5, 2021
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  3. tensa4

    tensa4 Member

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    Congratulations Ali!
    More motivation for me :)
     
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  4. Alibro

    Alibro Well-Known Member

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    So I have the pack opened and quite a few of the HV leads disconnected so it's no longer as dangerous. Obviously each module can deliver around 300A at 14V so while it won't give a shock it won't appreciate any metal tools being dropped on it. :eek:

    This is the layout of the modules and Pixie path from pack the most positive to most negative.

    IMG_20210407_181803154.jpg IMG_20210407_102642723.jpg

    Next step is to trace out all the BMS and CAN connections, label them and dismantle the pack so I can rebuild it on the bench for testing..
     
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  5. Nodge68

    Nodge68 Well-Known Member

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    Excellent Ali. The modules are arranged in a very strange way though. :confused:

    Looking forward to seeing it all working on the bench.
     
  6. Jayridium

    Jayridium Well-Known Member

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    Impressive work mate, I feel much happier now you've called it the pixie path. The other day I was soldering new terminals onto a much smaller LIPO battery, I don't envy you working on that system.
     
  7. Alibro

    Alibro Well-Known Member

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    I've been building ebike batteries for a couple of years now so I'm very aware of the danger of complacency. They don't have anything like the voltage but still bite if your not careful so I was relieved to break the pack down to sensible voltages.
     
  8. Alibro

    Alibro Well-Known Member

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    You're right mate, it took bloomin ages to trace the path as so many of the connections are buried in the pack. It will be days before I have the pack out and on the bench as I have a lot of labelling to do.
     
  9. andyfreelandy

    andyfreelandy Well-Known Member

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    I'm sure I've missed this, so apologies, but what voltage is the motor you have fitted? Does E stuff use a variable voltage essentially to control speed or is it more complex?
    Brain is still ICE focused and that's probably where it will stay!
     
  10. Nodge68

    Nodge68 Well-Known Member

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    Almost all EV motors are 3 phase electric motors, so the speed is altered by switching each phase in turn. The voltage and current determines how hard the motor can rotate (the torque) but the switching of the motor, determines the motor's speed of rotation.
    The Leaf motor runs at over 400V, which gives it plenty of torque, especially if used with a variable gear ratio of the FL1 gearbox.

    When Ali drove it in the video, he was using a small 36v Ebike battery pack, and an 800W Ebike motor controller, which is why it moved so slowly, but also shows just how efficient an electric drive can be.
     
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  11. andyfreelandy

    andyfreelandy Well-Known Member

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    Thanks John, that helps. The motor obviously turns at more or less any voltage which is useful for testing.
     
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  12. Nodge68

    Nodge68 Well-Known Member

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    You're welcome Andy.

    Yes the fact that Ali can use a much lower voltage, and current for testing, is really helpful, and much safer that messing about with high voltage and high current capable batteries.
     
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  13. Alibro

    Alibro Well-Known Member

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    Correct John.
    Also if I use the battery pack as it is I will be loosing some power compared to a leaf. The Leaf pack is 96S so approx 96 x 4. The eGolf pack is 88S or 88 x 4 so a much lower voltage.
    I suspect the inverter will be current controlled so the max power will be reduced.
    All this is still to be confirmed of course.
     
  14. Alibro

    Alibro Well-Known Member

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    Making a start stripping the pack, I'm taking it slow and labelling everything as I disconnect it so I can reconnect it all correctly on the bench.
    IMG_20210408_185928679.jpg IMG_20210408_215640480.jpg IMG_20210408_220849312.jpg
     
  15. Nodge68

    Nodge68 Well-Known Member

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    That's an interesting construction Ali.
    What dimensions are the modules used in this pack?
    Is it cooled?
     
  16. kernowsvenski

    kernowsvenski Well-Known Member

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    Just wondering, what age is the battery pack? What's the anticipated life of the cells?
     
  17. Alibro

    Alibro Well-Known Member

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    I haven't measured them yet John but the great news is they came at pretty much perfect storage Voltage, around 3.7V per cell. and no cooling that I can find. This would lead me to believe they are pretty under stressed delivering around 300A

    The pack is from a 2020 eGolf that had driven approx 167 miles so basically delivery mileage. :eek:
    It looks like it fell off the transporter when being delivered. One wheel was smashed off completely and another was only just hanging on. I noticed the brakes were still shiny and new looking on the inside of the vents with no signs of wear at all.
    Cell life should be around 10 years or 100k to 150k miles if looked after properly

    This is it.
    eGolf2.jpg
     
  18. Nodge68

    Nodge68 Well-Known Member

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    15 years, or about 150k miles. This battery will outlast the FL1. ;)

    I'm thinking Ali might need to convert an FL2 at some point in the future, as FL1s will get harder to fine. :(
     
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  19. Nodge68

    Nodge68 Well-Known Member

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    That's excellent, and shows the BMS is doing its job, but on a new battery pack, I'd not have expected anything else.
    That's interesting.
    Maybe VW have developed a heat tolerant battery? Or maybe it's simply too large a capacity to be stressed in this application.

    Are you going to find some more cells, to increase its voltage?
     
  20. Alibro

    Alibro Well-Known Member

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    I haven't decided whether to buy more or not yet John. I would need two of the 4S modules and they are going for over £500 each so if I can manage it another way I will.
    Another option is to purchase the second pack from EVBreakers, break it up and sell the bits I don't need but that would be a big financial risk.
     
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