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You are currently browsing the Rob’s RAVolt! weblog archives for the day May 29, 2007.

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Archive for May 29, 2007

Vacuum pump & switch have a home in the RAVolt

I’ve finally figured out where to place the vacuum pump and vacuum switch (pump on/off). The pump can sit flat on the battery rack under the brake cylinder on a (TBD) mounting board.  The switch gets packed with foam into a small cavity just below the wiper motor. The switch is secured to the body using a large ring clamp and the foam is needed to provide some extra mounting support.

Vacuum Pump  Vacuum switch

Unfortunately, the switch has no external mounting!

Ground control board to Major Tom?

I managed to cut my MDO board to create the base shape for the control board. The control board will have the main electronics (controller, contractors, pot box, etc) for the car. It came green, but I’m painting it day-glow blue. I’ve got to create the circuit diagrams and layout of the components (picture left to right: pot box, controller, contactors, ammeter shunt, fuse, Anderson-350 connector). I’m certain that I’ll need to go shopping to finish it, but EVAmerica sent nearly everything I need to get started.

Control board in car Control Board Components
One of my objectives with the control board is be able to quickly remove the control board as a unit. That means that all wiring to the board is able to quickly disconnect so I’ll need at least three high load Anderson connectors (traction batteries, motor, aux battery)

The AustinEV team also suggested that I add a high current DC breaker on the rear pack. I should have a pull string on the breaker so that the driver can quickly kill power to the whole system. I have a good location for the breaker between the back seat and the rear box.

Neo, take the red pill!

This blue pill would be way too big to swallow. The vacuum reservoir mounts to a steel bar screwed to the firewall using 4″ ring clamps. The tube is not heavy and should not vibrate, but I added foam to provide a little cushion and keep the tube from getting scratched. Note: There is a minor ground conduction hazard from the clamps.

Mount and rings Vacuum tube mounted
The tube is very secure in this position and this space above the batteries would be hard to fill otherwise.  This fuzzy bonus picture shows that my fossil fuel mascot trying to undermine the EV progress.  He’d better not try to bite the battery cables!
Angry Dino

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