Cool car Dave!
I've been thinking about heat lately too and I'd like to hear your and others opinions.
I'm going to install my controller assembly and motor as a single unit with the motor box over and sound insulation. I need to pull air through the case for cooling. Fresh air will come up from below the box and then needs to go somewhere from there being pushed with a fan. I'd rather not vent out the side of the box because of the heat and noise going into the cabin. Venting out the back under the cockpit just puts the heat into the battery space which isn't good for the batteries and without an outlet from there would just gradually heat up that larger space.
Thinking too about venting the batteries during use and charging (for the H), I could set up an axial fan and duct like in an inboard gas set up with the fan venting through a clam vent into the cockpit.
How much has heat management been an issue for others? My boat will be cruising in high ambient temperatures and the motor and controller will be in the same small insulated box. I could mount the controller and associated items separately and outside the motor box if that would really help but if I have to force air cool both they might as well be together.
My second question about heat is whether anyone is using an infrared thermometer to check things? I've heard of engine mechanics using one with a laser sight to check individual parts of the engine when running and then be able to compare that later to running temperatures to catch things like bearings going bad or exhausts running too hot.
Thanks,
David
Jim
Excellent writeup. It's very helpful to see real numbers showing whats
going on. It looks like you've put a lot of effort into this.
First, a little introduction. I've been watching this list for a while
but do not have a boat of my own yet. I'm still in the planning stage.
I live in New England and hope to start out by sailing in Long Island
Sound. I commend you guys for the work you've done and look forward to
"joining the fleet." I learn something new with everything I read
here.
I own and drive and electric car, so I have a slightly different slant
on electric propulsion. There's a link to my car at the bottom of this
email. While many of the parts, concepts and terms are the same,
moving a boat through water is a lot different than rolling a car on
pavement. Driving a car, it's not unusual to pull 700 amps from my
pack taking off from a stop. Cruising the hills where I live I will
draw between 75 to 300 amps on a regular basis. Not what you guys see
sailing. I'm not here to tell anyone how to sail, I'm the newbie.
Ok, enough of the introduction.
You bring up a very good point that I haven't seen mentioned before,
heat. Heat is usually an indicator of inefficiency or problems with
electric drives. But even when it's a product of working hard, you
need to manage it. Your comments on forced air cooling are very
important and I hope more people keep this in mind when repowering
with electric. With a motor, heat can be most damaging when you try
and push a lot of current through a motor at low RPMs. Cars often see
this when starting from a dead stop, and I imagine a boat would almost
never have this. So cooling over a long cruise is probably more the
issue. Your comments on heat are spot on.
But heat can also rear it's ugly head in other ways. With your main
wiring (from pack to controller and controller to motor) you should be
aware of heat issues. If you have a loose battery connection it can
heat up enough to melt a battery post right off. It doesn't hurt to
feel (safely, don't get shocked) around after running electric to see
if any wires or connections are warming up. If you find a hot spot,
you need to address it. This applies to all the components in your
electric drive. I even have liquid cooling for my controller.
Controllers are probably more prone to heat failures than motors. If
any of you are running Curtis controllers, or any controllers that are
designed to dissipate heat through the case, be very careful how you
mount it. Mounting your controller on a vertical aluminum plate and
adding a simple 12v fan can save you hundreds or thousands of dollars.
Also, batteries can generate heat during charge and discharge. If
you're in the tropics and running hard, you should provide some
cooling to the pack. Most good chargers will have a way to monitor
pack temperature and adjust the charge to compensate. I have flooded
NiCad cells in my pack and I ventilate them during every charge. I
usually charge right after a drive, so they are a little warm to start
with. No sense in letting them overheat. This is mainly for the
hydrogen, but also to cool them. Don't forget, anyone with flooded
batteries must control the hydrogen! Floodies have great capacity but
require more care. Not sure if it's worth it in a boat. I'd avoid
them.
Jim, you also put a lot of effort into understanding the efficiency of
the propeller, but I didn't see much mentioned about the efficiency of
the motor. Electric motors have an RPM sweet spot for efficiency and
this should be incorporated in the calculations. While you will vary
the speed for maneuvering around the harbor, you should design your
drive to use the most efficient RPM range for long cruises. In normal
driving my motor runs from 0 to 4000 RPMs, but it likes to be around
2500 to 3000. So I plan my driving accordingly. I won't always shift
into a higher gear as you might with a gas powered car. I know,
sailing is different, but your should be aware of your motor speed and
use it most efficiently. The biggest mistake is to run your motor too
slow with too much current. This generates heat and heat is a problem.
Anyway, the ElectricBoats list has been great and I'm learning a lot.
Didn't mean to run off at the mouth like this. As I said in the
beginning, I know a lot about electric cars, but very little about
electric boats. I don't know when I'll have my own to sail, but I'm
working on it. If anyone in Connecticut want's some help with their
electric drive, I'd love to lend a hand.
Dave Cover, learning all the time
--
http://www.evalbum.com/2149
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