Electric Motors for Hybrid Conversions
There are a number of ways to convert a traditional vehicle into an electric hybrid. Various methods include coupling the electric motor to the driveshaft, transmission or directly to the gas engine. Additional options include wheel motors and axle couplers.
Brussless DC, Brushed DC and AC motors are available for your conversion. A few options are shown below:
one step at a time
For this hybrid conversion, we choose on a BLDC, permanent magnet synchronous motor from http://www.motenergy.com. This motor has a low power to weight ratio, excellent regenerative capabilities and was affordably priced.
Output Power of 12 KW Continuous, 30 KW Peak (at 96 volts)
Designed for long life. No brush maintenance. The motor is 92% efficient at voltages between 24 to 96 VDC. Continuous current of 125 amps AC (180 Amps DC into the motor control). This is a 3-phase, Y-connected Permanent Magnet Synchronous Motor with an axial air gap and 3 Hall sensors at 120 degrees electrical timing. It has two stators with a rotor in the center.
1) This is a 4 pole motor (8 magnets). 2) The Phase to Phase winding resistance is 0.013 Ohms. 3) The maximum recommended rotor speed is 5000 RPM. 4) Voltages from 0 to 96 VDC input to the control. 5) Torque constant of 0.15 Nm per Amp 6) The Inductance Phase to Phase is 0.10 Milli-Henry with a 28 turns per phase. 7) Armature Inertia is 45 Kg Cm Squared. 8) Continuous current of 125 Amps AC (180 Amps DC into the motor control). 9) Peak current of 420 Amps AC for 1 minute (600 Amps DC into the motor control). 10) Weight of 35 pounds. 11) Peak Stall Torque if 90 Nm. 12) This is an Open Frame, Fan Cooled motor.
Includes temperature sensor.
Wiring the Kelly Controller to this BLDC Motor does require the following installation (kellycontoller.com):
Making the decision on how big of an electric motor I could fit into the Mustang without destroying any of the classic panels, came down to old fashion cardboard models!
Wheel hub motor with a disc brake:
TransWarP DC motor with the driveshaft connection:
WarP DC motor:
After a lot of searching, the two best places for the electric motor seemed to be on the drives side using the AC mounting location or on the passenger side using the alternator mounting location. An alternator replacement was ultimately chosen as this component is no longer needed!
Mounting the ME0913 electric motor required additional brackets and mounting fabrication. The end result with an oversized belt seems to work very well but a ribbed belt/pulley would be required to reliability start the gas engine without the starter motor.