All Green Vehicles is the leading supplier of electric vehicles in the Netherlands. We take a look at some of their more interesting offerings.
Starting with the drivetrain, DC brushless motors were chosen as this type of electric motor is more efficient, more compact and has lower cooling requirements than your typical AC induction motors, which are of course, cheaper. The motor has been mounted to maintain the crumple zones essential for crash safety.
The motor controller is coupled with the LiTHIUM BALANCE Battery Management System to ensure the drivetrain utilises the batteries safely and efficiently. The BMS broadcasts continuously over CAN to provide the drivetrain with battery status information, such as SoC, allowable discharge and regen (regenerative braking) currents. Errors and warnings are also broadcast over CAN allowing the drivetrain to make intelligent safety decisions.
The transmission is a single speed, reduction gearbox. The usual trick of vehicle converters, using the standard gearbox and fixing it in second gear, removes some of the benefits of the electric drivetrain including efficiency, with more meshing gear sets creating losses and torque transfer, electric motors generate high levels of torque at low speed, far in excess of what an internal combustion engine of a similar power would deliver. This means that the electric motor needs to be down rated to prevent it from stripping the cogs in a normal gearbox.
The dashboard instruments have been professionally customised so that the warning lights are for an electric drivetrain rather than the original ICE, the gear shifter is also a dedicated unit for the electric drivetrain, giving an overall impression of being in an OEM manufactured vehicle.
On the road, the common mistakes of mounting the brake vacuum pump too close to the engine bay bulkhead, so that you can hear it hammering away intrusively every time you hit the brakes are absent, as is steering pump whine. A lot of work was done to reverse engineer the vehicle onboard electronics so that all the electronic features of the original vehicle are still present such as ABS brakes, airbags, the in car entertainment system and the heating system. The heating system is of course supplemented with an additional electric heating element.
This represents the perfect marriage of application to solution. Trucks are typically noisy, smelly brutish things with complicated gearboxes and noisy brakes. When used in an urban environment to deliver goods from depots to sales outlets, we all know how poorly they fit in.
The AGV MAN benefits from the torque rich nature of an electric drivetrain, once again using a brushless DC motor, to provide near silent travel and a relaxing driving experience as the vehicle moves away from standstill up to 100km/h without a single gear change and very little noise beyond the gentle wind rustle around the cabin.
With a modular 120kWh battery pack onboard located in 5 boxes, both sides and in between the chassis rails, and a short motor bolting directly to the axle differential, the packaging is exceptionally neat allowing coachbuilders to mount vehicle bodies without any compromise on space or positioning.
The battery is controlled by the LiTHIUM BALANCE s-BMS system which communicates with the motor controller providing safe charging and operation including a gradual reduction of power as the battery SoC drops to extend range and protect the batteries. On such heavy vehicles, the application of regenerative braking provides real benefits lessening braking loads while saving energy.
Once again, masterful work has been done to reverse engineer the chassis electronics to provide a fully functioning cabin and dashboard and the overall fit and finish is of the highest order.
Frost & Sullivan presented LiTHIUM BALANCE Battery Management Systems A/S with the ‘2009 European Automotive Powertrain New Product Innovation Award’. Points that counted in LiTHIUM BALANCE’s favour, according to Frost & Sullivan Research Analyst Bharath Kumar Srinivasan were the vehicle-to-grid features and the significant life extension of battery cells due to the s-BMS’s performance. The extended battery life translates to sustained vehicle performance over time.
LiTHIUM BALANCE was also a runner up in the Eurecan European Venture Contest which saw 987 applicants from all over Europe compete for the top honors. LiTHIUM BALANCE represented by Lars Barkler made it through, first to the last 150, before going on to the last 25 and finally ending up second in the Cleantech category. More cause for celebration!