China Loves Battery Swapping EVs, But Will They Ever Make It Here?

February 9, 2022 by Lewin Day 122 Comments

Electric vehicles promise efficiency gains over their gas-fuelled predecessors, but the issue of recharging remains a hurdle for many eager to jump on board with the technology. The problem is only magnified for those that regularly street park their vehicles or live in apartments, without provision to charge a vehicle overnight at home.

Battery swapping promises to solve that issue, letting drivers of EVs change out their empty battery for a freshly charged one in a matter of minutes. The technology has been widely panned and failed to gain traction in the US.

However, as it turns out, battery swapping for EVs is actually thing in China, and it’s catching on at a rapid rate.

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Swapped Dash Module Gives Ford Maverick An Upgrade

February 7, 2022 by Tom Nardi 17 Comments

Ford is looking to make their new Maverick compact truck stand out, and so far, it seems to be working. Not only is it exceptionally cheap for a brand-new hybrid, truck or otherwise, but Ford actively encourages owners to modify their new ride. From standardized mounting points throughout the cabin intended for 3D printed upgrades, to an auxiliary 12 VDC line run to the bed specifically for powering user supplied hardware.

But we doubt even the most imaginative of Blue Oval engineers could have predicted that somebody would rip out the whole dash module and replace it with one from a higher-end Ford this early in the game. While many people can’t even find one of these trucks on the lot, [Tyvemattis] on the Maverick Truck Club forum has detailed his efforts to replace the relatively uninspired stock dash module of his truck with an all-digital version pulled from a 2020 Ford Escape Titanium.

Ford’s rendering of the original Maverick dash module.

Now we say “effort”, but as it turns out, the swap went off nearly without a hitch. The new digital module not only appears to be the identical size and shape as the original, but they both use the same connectors. Presumably this is because both vehicles are based on Ford’s scalable C2 platform, and likely means more components from this family of vehicles such as the Lincoln Corsair or new Bronco could be installed into the Maverick.

So what’s the downside? According to [Tyvemattis], the computer is throwing error messages as the Maverick doesn’t have a lot of the hardware that the dash is trying to communicate with. He also can’t change the vehicle’s driving mode, and the cruise control can only be enabled when the truck is stopped. But probably the most annoying issue is that the fuel gauge is off by 50%, so when the tank is full, it shows you’ve only got half a tank. At least one other user on the forum believes this could be alleviated by modifying the fuel sensor wiring, so it will be interesting to see how difficult a fix it ends up being.

We first ran across the DIY-friendly Maverick back in October of last year, and we’re encouraged to already see owners answering Ford’s challenge by tinkering with the vehicle. Here’s hoping this is the start of a new chapter in the long and storied history of car hacking.

Thanks to [Matt] for the tip.

Arduino Activated Automotive Aerodynamic Apparatus Is… (Spoiler Alert!)

February 3, 2022 by Ryan Flowers 8 Comments

Sometimes a great hack is great for no other reason than that it’s fun, and [Michael Rechtin]’s DIY Active Aero Spoiler and Air Brake certainly qualifies as a fun hack. This is a mod designed to live in a world where looks are everything, stickers add horsepower, and a good sound system is more important than good wheel alignment. Why is that? Because like the switch that exists only to activate the mechanism that turns it off, the DIY Active Aero Spoiler and Air Brake seen below is almost completely useless. So to understand its allure, we must understand its inspiration.

For a few decades now, luxury sports car manufacturers have been adding active aerodynamic components to their vehicles. For example, several Porsche models feature adaptive spoilers that adjust to driving conditions. Super cars such as the Bugatti Veyron have spoilers that flip up at high angles during braking to increase drag and reduce braking distance. All of these features are sadly missing from the average two or four door family-car-turned-wannabe-track-fiend. Until now!

[Michael] has created a new active spoiler for every mall-bound muffler-challenged hand me down. The build starts with a CNC cut foam wing which is covered with fiberglass, Bondo (an automotive necessity) and some faux carbon fiber for that go-fast feel. An Arduino, IMU, two servos, and a battery pack detect deceleration and automatically increase the spoiler angle just like the big boys, but without needing any integration into the vehicles systems. Or bolts, for that matter.

It’s unlikely that the braking force is enough to slow down the vehicle though, given that it’s not enough to pop the suction cups holding it to the trunk lid. But does it have the “wow” factor that it was designed to induce? Spoiler Alert: It does!

As it turns out, this isn’t the first adjustable spoiler featured here at Hackaday, and this adjustable spoiler on a car that’s made for actual racing is quite interesting.

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Hacking A Proper Dash Into The Tesla Model 3

January 28, 2022 by Lewin Day 60 Comments

The Tesla Model 3 and Model Y are popular electric vehicles that dispense with some of the usual provisions you’d expect in a typical car. Namely, there’s no dash cluster in front of the driver; instead, all information is solely displayed on the center console screen. [Nick Nguyen] wasn’t a fan of this setup, and decided to hack together a dash cluster of his own.

The CANdash works in a simple fashion, snooping the Tesla’s CAN bus for all the information relevant to the vehicle’s operation. It’s capable of displaying everything from speed to the remaining range in the battery, while also allowing the user to keep an eye on things like coolant temperatures and whether the Tesla Autopilot system is currently available.

The build relies on a CANserver, an ESP32-based device specifically built for hooking up to the CAN bus on Tesla vehicles and sharing the data externally. The data can then be piped wirelessly to an Android phone running CANdash to display all the desired information. With the help of an aftermarket dash clip or a 3D printed custom mount, the phone can then be placed behind the steering wheel to display data in the usual location.

It’s a simple, straightforward hack that gives Tesla owners a useful feature that they’re otherwise missing from the factory. The US automakers cars are proving to be fertile ground for hackers and DIYers, with one man recently saving thousands on a battery swap with a simple mod. Video after the break.

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Longer Range EVs Are On The Horizon

January 19, 2022 by Lewin Day 165 Comments

When electric cars first started hitting the mainstream just over a decade ago, most criticism focused on the limited range available and the long recharge times required. Since then, automakers have been chipping away, improving efficiency here and adding capacity there, slowly pushing the numbers up year after year.

Models are now on the market offering in excess of 400 miles between charges, but lurking on the horizon are cars with ever-greater range. The technology stands at a tipping point where a electric car will easily be able to go further on a charge than the average driver can reasonably drive in a day. Let’s explore what’s just around the corner.

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Making Your Own Mclaren F1 LM

January 14, 2022 by Matthew Carlson 14 Comments

It isn’t often we get a project that has an eighteen-year-long timeline, as staying focused on one project for that long is a significant investment of someone’s lifetime. But when you’re making your own carbon copy Mclaren, you need to be prepared for it to take a while. Unfortunately, there are only 6 of them in the world so for most people if you want one, you need to make your own.

Granted, in those eighteen years, [Brough Built] freely admits there were some gaps. He scrapped most of the earlier work, and today’s current iteration took about three years. This car is made of steel, aluminum, foam, carbon fiber, and sweat. It is a close copy of the F1, and it has all the features you would expect to see on the real thing, like the centered driver’s seat and the gold cladding in the engine bay.

A BMW V12 engine mated to an Audi six-speed gearbox provides the power inside the car. A custom clutch assembly was machined to make it all work. Overall, this is an incredible build with time, and precision just poured into it. Folding and cutting all that metal alone, not to mention all the meticulous welds on everything from the gas tank to the door panels.

Making your own car is a complex and long journey that can be incredibly rewarding. Perhaps not a copy of an existing vehicle but something new; check out this soap shaped hand-made electric car.

Exploring Tesla Model S High Voltage Cabling

January 13, 2022 by Chris Lott 36 Comments

When he’s not busy with his day job as professor of computer and automotive engineering at Weber State University, [John Kelly] is a prolific producer of educational videos. We found his video tracing out the 22+ meters of high voltage cabling in a Tesla Model S (below the break) quite interesting. [John] does warn that his videos are highly detailed and may not be for everyone:

This is not the Disney Channel. If you are looking to be entertained, this is not the channel for you.

We ignored the warning and jumped right in. The “high” voltages in the case of an electric vehicle (EV) like the Model S is approximately 400 volts. Briefly, external input via the charge connector can be single or three phase, 120 or 250 VAC, depending on your region and charging station. This get boosted to a nominal 400 VDC bus that is distributed around the various vehicle systems, including the motors and the battery pack.

Rear Modules

- Charge receptacle
- On-board charger module
- Rapid splitter
- Rear motor inverter

Front Modules

- High voltage junction block
- Cabin air heater
- DC to DC converter
- Battery coolant heater
- Air conditioning compressor
- Front motor inverter

He goes through each module, showing in detail the power routing and functionality, eventually assembling the whole system spanning two work benches. We liked his dive into the computer-controlled fuse that recently replaced the standard style one, and were impressed with his thorough use of labels.

If you’ve ever been curious about the high voltage distribution of a EV, grab some popcorn and check out this video. Glancing through his dozens of playlists, [John]’s channel would be a good place to visit if you’re interested any topic related to hybrids and electric vehicles, drive trains, and/or transmissions. We’ve written about some Tesla teardowns before, the Model 3 and the Model S battery packs. Have you worked on / hacked the high voltage system in your EV? Let us know in the comments below.

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