Electric Vehicle Charging Heats Up

January 22, 2025 by Bryan Cockfield 64 Comments

As the electric vehicle takeover slowly lumbers along, marginally increasing efficiencies for certain applications while entrenching car-centric urban design even further, there are some knock-on effects that are benefiting people and infrastructure beyond simple transportation. Vehicle-to-grid technology has applications for providing energy from the car back to the grid for things like power outages or grid leveling. But [Technology Connections] is taking this logic one step further. Since a large number of EV owners have charging stations built into their garages, he wondered if these charging stations could be used for other tasks and built an electric heater which can use one for power.

This project uses a level 2 charger, capable of delivering many kilowatts of power to an EV over fairly standard 240V home wiring with a smart controller in between that and the car. Compared to a level 1 charger which can only trickle charge a car on a standard 120V outlet (in the US) or a DC fast charger which can provide a truly tremendous amount of energy in a very short time, these are a happy middle ground. So, while it’s true a homeowner could simply wire up another 240V outlet for this type of space heater or other similar application, this project uses the existing infrastructure of the home to avoid redundancies like that.

Of course this isn’t exactly plug-and-play. Car chargers communicate with vehicles to negotiate power capabilities with each other, so any appliance wanting to use one as a bulk electric supply needs to be able to perform this negotiation. To get the full power available in this case all that’s needed is a resistor connected to one of the signal wires, but this won’t work for all cases and could overload smaller charging stations. For that a more complex signalling method is needed, but since this was more of a proof-of-concept we’ll still call it a success. For those wanting to DIY the charger itself, building one from the ground up is fairly straightforward as well.

Thanks to [Billy] for the tip!

Continue reading “Electric Vehicle Charging Heats Up” →

Turning A Lada Into An EV With 50 Cordless Drills, Because Why Not?

January 1, 2025 by Donald Papp 47 Comments

[Garage 54] is no stranger to vehicle-related projects of the “because why not?” variety, and their latest is using 50 cordless drills combined into a monstrous mega-motor to turn a gutted (and extended) Lada into an electric vehicle (EV).

Doing this leans on some of [Garage 54]’s earlier projects, such as replacing the aforementioned Lada’s engine block with a frame containing sixteen chainsaws. That means they don’t need to start completely from scratch, and have a frame design that can drop into the vehicle once the “engine” is constructed.

Fifty cordless drills won’t set any efficiency records for EV engines, but it’s got a certain style.

Here’s what’s in the new engine: each of the drills has its chuck replaced with an aluminum pulley, and belts connect each group of drills to an output shaft. Ideally, every drill motor would run at the same time and at exactly the same speed, but one works with what they have. [Garage 54] originally worked to synchronize the drills by interfacing to each drill’s motor control board, but eventually opted to simply bypass all controls and power each drill’s motor directly from the batteries. Initial tests are done by touching bare cable ends with a turned-away face and squinted eyes, but we expect “Just A Big Switch” to end up in the final assembly.

It looks wild and we can think of more than a few inefficiencies present in a system like this, but the output shaft does turn and torque is being transferred, so the next step is interfacing to the car’s factory gearbox.

If it powers the car in any meaningful way, that Lada might very well become the world’s most gloriously hacked-together EV. And hey, if the power output of the EV motor is disappointing, you can just make your own.

Continue reading “Turning A Lada Into An EV With 50 Cordless Drills, Because Why Not?” →

Hackaday Links: October 27, 2024

October 27, 2024 by Dan Maloney 14 Comments

Problem solved? If the problem is supplying enough lithium to build batteries for all the electric vehicles that will be needed by 2030, then a new lithium deposit in Arkansas might be a resounding “Yes!” The discovery involves the Smackover Formation — and we’ll be honest here that half the reason we chose to feature this story was to be able to write “Smackover Formation” — which is a limestone aquifer covering a vast arc from the Rio Grande River in Texas through to the western tip of the Florida panhandle. Parts of the aquifer, including the bit that bulges up into southern Arkansas, bear a brine rich in lithium salts, far more so than any of the brines currently commercially exploited for lithium metal production elsewhere in the world. Given the measured concentration and estimated volume of brine in the formation, there could be between 5 million and 19 million tons of lithium in the formation; even at the lower end of the range, that’s enough to build nine times the number of EV batteries needed.

Continue reading “Hackaday Links: October 27, 2024” →

Hackaday Links: September 29, 2024

September 29, 2024 by Dan Maloney 16 Comments

There was movement in the “AM Radio in Every Vehicle Act” last week, with the bill advancing out of the US House of Representatives Energy and Commerce Committee and heading to a full floor vote. For those not playing along at home, auto manufacturers have been making moves toward deleting AM radios from cars because they’re too sensitive to all the RF interference generated by modern vehicles. The trouble with that is that the government has spent a lot of effort on making AM broadcasters the centerpiece of a robust and survivable emergency communications system that reaches 90% of the US population.

The bill would require cars and trucks manufactured or sold in the US to be equipped to receive AM broadcasts without further fees or subscriptions, and seems to enjoy bipartisan support in both the House and the Senate. Critics of the bill will likely point out that while the AM broadcast system is a fantastic resource for emergency communications, if nobody is listening to it when an event happens, what’s the point? That’s fair, but short-sighted; emergency communications isn’t just about warning people that something is going to happen, but coordinating the response after the fact. We imagine Hurricane Helene’s path of devastation from Florida to Pennsylvania this week and the subsequent emergency response might bring that fact into focus a bit.

Continue reading “Hackaday Links: September 29, 2024” →

Hackaday Links: July 14, 2024

July 14, 2024 by Dan Maloney 11 Comments

We’ve been going on at length in this space about the death spiral that AM radio seems to be in, particularly in the automotive setting. Car makers have begun the process of phasing AM out of their infotainment systems, ostensibly due to its essential incompatibility with the electronics in newer vehicles, especially EVs. That argument always seemed a little specious to us, since the US has an entire bureaucracy dedicated to making sure everyone works and plays well with each other on the electromagnetic spectrum. The effort to drop AM resulted in pushback from US lawmakers, who threatened legislation to ensure every vehicle has the ability to receive AM broadcasts, on the grounds of its utility in a crisis and that we’ve spent billions ensuring that 80% of the population is within range of an AM station.

Continue reading “Hackaday Links: July 14, 2024” →

Making EV Motors, And Breaking Up With Rare Earth Elements

July 9, 2024 by Donald Papp 85 Comments

Rare earth elements are used to produce magnets with very high strength that also strongly resist demagnetization, their performance is key to modern motors such as those in electric vehicles (EVs). The stronger the magnets, the lighter and more efficient a motor can be. So what exactly does it take to break up with rare earths?

Rare earth elements (REEs) are actually abundant in the Earth’s crust, technically speaking. The problem is they are found in very low concentrations, and inconveniently mixed with other elements when found. Huge amounts of ore are required to extract useful quantities, which requires substantial industrial processing. The processes involved are ecologically harmful and result in large amounts of toxic waste.

Moving away from rare earth magnets in EV motors would bring a lot of benefits, but poses challenges. There are two basic approaches: optimize a motor for non-rare-earth magnets (such as iron nitrides), or do away with permanent magnets entirely in favor of electromagnets (pictured above). There are significant engineering challenges to both approaches, and it’s difficult to say which will be best in the end. But research and prototypes are making it increasingly clear that effective REE-free motors are perfectly feasible. Breaking up with REEs and their toxic heritage would be much easier when their main benefit — technological performance — gets taken off the table as a unique advantage.

Nine men of various ages and ethnicities stand in a very clean laboratory space. A number of large white cabinets with displays are on the left behind some white boards and there are wireless charging coils on a dark tablecloth in the foreground. In the back of the lab is a white Porsche Taycan.

Polyphase Wireless EV Fast Charging Moves Forward

June 21, 2024 by Navarre Bartz 85 Comments

While EV charging isn’t that tedious with a cable, for quick trips, being able to just park and have your car automatically charge would be more convenient. Researchers from Oak Ridge National Lab (ORNL) and VW have moved high-speed wireless EV charging one step closer to reality.

We’ve seen fast wireless EV chargers before, but what sets this system apart is the coil size (~0.2 m² vs 2.0 m²) and the fact it was demonstrated on a functioning EV where previous attempts have been on the bench. According to the researchers, this was the first wireless transfer to a light duty vehicle at 270 kW. Industry standards currently only cover systems up to 20 kW.

The system uses a pair of polyphase electromagnetic coupling coils about 50 cm (19″) wide to transfer the power over a gap of approximately 13 cm (5″). Efficiency is stated at 95%, and that 270 kW would get most EVs capable of those charge rates a 50% bump in charge over ten minutes (assuming you’re in the lower part of your battery capacity where full speeds are available).

We’ve seen some in-road prototypes of wireless charging as well as some other interesting en route chargers like pantographs and slot car roads. We’ve got you covered if you’re wondering what the deal is with all those different plugs that EVs have too.

Continue reading “Polyphase Wireless EV Fast Charging Moves Forward” →