AC Propulsion AC-150 EV Power System

Second Generation AC-150 Drivetrain

The new second generation AC-150 drivetrain is now available. The new system retains the original's 150 kW (200 HP) rating, but has fewer parts, is 30 percent smaller, 8 pounds lighter and packages more functions inside the electronics enclosure than the original AC-150 drive system. The most significant new feature is the integral 20-kW bi-directional grid power interface. The integrated grid interface was originally developed to serve as a high-power battery charger for battery electric vehicles. With the bi-directional capability, many new applications are opened up for electric drive vehicles of all types, including distributed generation, selling grid ancillary services, automated battery diagnostic discharge testing, and using vehicles to provide uninterruptible backup power to homes or businesses. (.pdf specifcation sheet)

New features of the second generation AC-150 drive train include:

Bi-directional AC power grid interface
Stand-alone power generation mode - power to AC loads
Waterproof automotive connectors
Integral automatic battery contactor inside the power electronics unit (PEU)
Quarter turn bayonet connector for battery connection
Digital interface for instrumentation and recharge control
Integrated DC bus power port for connection of hybrid engine, fuel cell, or supercapacitor
Refined motor control for higher power above base speed
RS232 serial port for laptop data displays
Improved traction control and regeneration with lateral acceleration compensation

Click here for more details on new features.

A new vehicle control computer (VCC) is also available as a companion product. The VCC coordinates battery management, recharging, energy monitoring, and AC grid interface functions. Features of the VCC include:

Interface and control for AC Propulsion BatOpt or VTM battery management systems
Displays for battery state of charge, Ah, Wh, regeneration Ah and Wh, net Wh/mile
RS232 serial port for laptop computer displays
Global Positioning System Option for location-specific grid services
Wireless bi-directional internet communications for remote dispatch of grid power services and remote diagnostics
Energy management algorithms to deploy grid power functions subject to driver range requirements.
Battery module-level upper and lower voltage limits for regeneration and motoring.

The AC-150 drive system leads the industry in peak and continuous power density both on volumetric and weight bases. The system delivers up to 150 kW (200 hp) motor output, yet maximizes vehicle operating range with high efficiency over a broad operating range and comprehensive energy recovery through traction-controlled regenerative braking. The copper-rotor induction motor weighs 50 kg (110) including its cooling system and produces 225 N-m (165 ft-lb) of torque from zero to 5000 rpm. The power electronics unit (PEU) weighs 30 kg including its cooling system, and houses the traction motor inverter, 20-kW bidirectional charger/grid interface, and 100-Amp 13.5V accessory power supply.

The AC-150 embodies patented control and construction techniques that allow the power electronics and motor windings to be re-configured as a high-rate Reductive battery charger. The AC-150 Reductive charging system can be plugged in to standard 120V, 208V or 240V outlets, and is compatible with existing level 2 conductive recharge stations, or with the new Level 2+ high power recharge stations for up to 20 kW of recharge power.

The Gen II AC 150 drive system is in pilot production and is available immediately. Contact info@acpropulsion.com for details.

SYSTEM FEATURES

Advanced Drive Control Circuitry

"Glass smooth" torque under all load and speed conditions
Natural and transparent driving feel
Driver adjustable regeneration
Traction control
Speed control available

Integrated Reductive Charger / Bidirectional AC power interface

Charge from any power source between 100 and 250 VAC
Nearly silent operation at normal charge rates (<10 kW)
Charge rate controllable from 200W up to 20kW (with 240 V line)
Unity power factor, sine wave current draw
6 mA GFI outlet compatible
Automatic mode switching (recharge mode activated when charge power is connected)
Compatable with delayed charging and rate control (utility interface)
Controlled battery discharge into power line for battery diagnostics and conditioning
UPS mode for backup power and energy transfer to other electric vehicles

Designed-in Safety

Protection against over-current, over-voltage and over-temperature conditions.
Battery floats with respect to vehicle chassis
Double insulated motor
Zero motor back-EMF when excitation removed
Interlocks prevent accidental operation

OPERATING PERFORMANCE

Voltage 336 - 360 V nominal, 240 V min, 450 V max
Current 580 A max (drive), -200 A max (regeneration)
Torque 220 Nm, 0-5,000 rpm (drive), 85 ft-lb max (regeneration)
Power 150 kW max 7,000-8,000 rpm, 50 kW continuous
Efficiency (shaft power out / electrical power in) (efficiency map)
91% peak ( 50 kW, 9,000 rpm)
86% road load (8 kW, 8,500 rpm)
>93% recharge (240V line, 10 kW) (recharge efficiency curve)

POWER ELECTRONICS UNIT

Pulse-width-modulated, voltage fed, IGBT inverter with current mode, sine-modulated controls; battery charging circuitry; auxiliary 13.5V power supply; and interfaces for control pedals and dash instruments. Environmentally rugged forced air-cooled design.
Dimensions*: 186 x 313 x 760 mm
Total weight: 30 kg (incl cooling blower)
Cooling: Forced-air with variable speed pwm control
Power connectors: Aircraft-style circular
Control connectors: AMP waterproof automotive
Control inputs: Ground-referenced signals for key switch, accelerator pedal, regenerative sensitivity, forward, neutral, and reverse; and recharge settings for line current, battery current, and battery voltage. Optional CAN bus.
Instrumentation outputs: Ground referenced signals outputs for battery voltage, battery current, motor temperature, electronics temperature, line voltage, line current, and LED status indicators.
Auxilliary power supply current**: 100 A @ 13.5 V

MOTOR

Four-pole induction, high frequency design with inverter-controlled magnetic flux.
Dimensions*: 12" dia x 15" long (305 mm dia x 381 mm long)
Total weight: 110 lb, 50 kg (incl cooilng blower)
Maximum rpm: 12,000
Insulation: Class H, double-insulated
Cooling: Forced-air with variable speed pwm control
Sensors: Winding temp, tachometer

* dimensions exclude blower and connectors
** up to 30 A allocated for cooling blowers

(.pdf specifcation sheet)