Toyota Rav4 EV Forum

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 Post subject: Longer Range Battery / Extra battery
PostPosted: Sun Nov 29, 2015 7:11 pm 
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Joined: Wed Nov 14, 2012 9:50 pm
Posts: 4068
Location: San Diego
I have a source of batteries that come in 18kWh modules.

They can also be heated / cooled, just like the current RAV4 EV, and they are cylindrical 18650 cells. Each module is 42.5" x 18" x 8".

The problems with this are as follows:

1) maximum voltage is a little below what the current pack is (90 in series instead of 92)

2) need to develop a BMS for the pack (Orion?)

3) need to add heating / cooling

4) need to develop mount


With about 70kWh usable onboard (two 18kWh packs) with the following ground speeds, and a composite 40kW charger rate to fill 50kWh useable each time requires 1.25 hrs at a CHAdeMO station.

Optimal speed is 75mph for lowest time traveled with 80% SOC charges, and traveling at 90-95% of the available range:

55mph - 4.0 miles/kWh * 70kWh = 280 miles @ 70% = 196 / 55mph = 3.6 hrs + 1.25 = 4.85hr = 40.4mph

65mph - 3.4 miles/kWh * 70kWh = 238 miles @ 70% = 166 / 65mph = 2.7 hrs + 1.25 = 3.95hr = 42.0mph

75mph - 2.7 miles/kWh * 70kWh = 189 miles @ 70% = 132 / 75mph = 1.7 hrs + 1.25 = 2.95hr = 44.7mph

85mph - 2.0 miles/kWh * 70kWh = 140 miles @ 70% = 98 / 85mph = 1.2 hrs + 1.25 = 2.45hr = 40.0mph

In a nutshell, two packs are proposed:

$12,000 rough estimate - 18kWh / 15kWh usable
$21,000 rough estimate - 36kWh / 30kWh usable

One 18kWh module will fit entirely in the third row footwell (the footwell must be cut out). The floor of the trunk would remain flat.

The second module would fit directly on top of the first module, raising the trunk floor by approximately 9".

All heaters / air conditioning compressors can fit in the rear corners.

Going forward to the front on the vehicle would be:

1) two DC cables tied to the main traction battery
2) isolation relay to separate the two packs
3) air conditioning high pressure lines to the additional radiator in the front
4) 12 volt power for the battery heater
5) 12 volt power for BMS

_________________

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Tony Williams
QC Charge
1780-104 La Costa Meadows Drive
San Marcos, California 92078 USA
tony@QCcharge.com
www.QCcharge.com
Twitter: QCPower
1-844-EV-PARTS
1-844-387-2787
1-760-798-0342 Office
Hours M-F, 9-5 Pacific Time


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 Post subject: Re: Longer Range Battery / Extra battery
PostPosted: Mon Nov 30, 2015 12:44 am 
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Joined: Sat Apr 26, 2014 4:09 pm
Posts: 164
Location: Shoreline, WA
Don't you mean FOUR 18kWh modules in order to have the 70kWh usable? Not two.

_________________
2013 Pearl White RAV4 EV - 45.5k miles
Tesla Model 3 Reserved Day 1 - Delivery 4/28/18
Solar Industry - 12 years (solar on house since 1989)
JESLA , JLONG , JDeMo, WeatherTech mats including cargo,
Bike Hitch, Mud flaps, cargo cover


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 Post subject: Re: Longer Range Battery / Extra battery
PostPosted: Mon Nov 30, 2015 1:28 am 
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Joined: Mon Oct 29, 2012 6:19 pm
Posts: 280
I think you are forgetting the 40+ kWh battery that you currently have. I believe Tony is talking about add-ons, not replacements (or am I off base?)


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 Post subject: Re: Longer Range Battery / Extra battery
PostPosted: Mon Nov 30, 2015 5:00 am 
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Joined: Wed Nov 14, 2012 9:50 pm
Posts: 4068
Location: San Diego
Yes, add-on batteries. We won't even touch the original battery.

So, 45-ish kWh plus 36kWh is 81kWh total, or about 70kWh usable.

At 3 miles per kWh (about 70mph), that's 210 miles of range.

_________________
Tony Williams
QC Charge
1780-104 La Costa Meadows Drive
San Marcos, California 92078 USA
tony@QCcharge.com
www.QCcharge.com
Twitter: QCPower
1-844-EV-PARTS
1-844-387-2787
1-760-798-0342 Office
Hours M-F, 9-5 Pacific Time


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 Post subject: Re: Longer Range Battery / Extra battery
PostPosted: Mon Nov 30, 2015 5:46 am 
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Joined: Sat Apr 26, 2014 4:09 pm
Posts: 164
Location: Shoreline, WA
I'm loving this! Sure hope you can figure out the missing pieces. And is this something you're seriously considering, or just musing over?

Where are you thinking of mounting these?

_________________
2013 Pearl White RAV4 EV - 45.5k miles
Tesla Model 3 Reserved Day 1 - Delivery 4/28/18
Solar Industry - 12 years (solar on house since 1989)
JESLA , JLONG , JDeMo, WeatherTech mats including cargo,
Bike Hitch, Mud flaps, cargo cover


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 Post subject: Re: Longer Range Battery / Extra battery
PostPosted: Mon Nov 30, 2015 8:13 am 
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Joined: Wed Nov 14, 2012 9:50 pm
Posts: 4068
Location: San Diego
Larry_in_Seattle wrote:
I'm loving this! Sure hope you can figure out the missing pieces. And is this something you're seriously considering, or just musing over?

Where are you thinking of mounting these?


Mount beneath the cargo, behind rear axle.

Yes, I'll probably do it on my car(s).

_________________
Tony Williams
QC Charge
1780-104 La Costa Meadows Drive
San Marcos, California 92078 USA
tony@QCcharge.com
www.QCcharge.com
Twitter: QCPower
1-844-EV-PARTS
1-844-387-2787
1-760-798-0342 Office
Hours M-F, 9-5 Pacific Time


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 Post subject: Re: Longer Range Battery / Extra battery
PostPosted: Mon Nov 30, 2015 5:07 pm 
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Joined: Mon Oct 29, 2012 6:19 pm
Posts: 280
I was #3 on the JdeMO list, hoping to be #1 on this list. Any idea of time frame and cost?


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 Post subject: Re: Longer Range Battery / Extra battery
PostPosted: Mon Nov 30, 2015 5:21 pm 
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Joined: Sat Sep 14, 2013 3:09 pm
Posts: 110
Location: New Jersey
TonyWilliams wrote:
Mount beneath the cargo, behind rear axle.


Cool! and you have the four hitch anchor points for mounting to work with maybe?

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2012 Toyota Rav4 EV BLIZZARD PEARL #99, JdeMO Equipped
Purchased used in Michigan with 2700 miles, shipped to New Jersey on 10/13/2013


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 Post subject: Re: Longer Range Battery / Extra battery
PostPosted: Mon Nov 30, 2015 5:32 pm 
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Joined: Thu Nov 19, 2015 12:09 am
Posts: 11
What is optimal speed with a jesla 40 amp level 2 charger, since 75 or 85 mph is not legal anywhere on public roads in California.


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 Post subject: Re: Longer Range Battery / Extra battery
PostPosted: Mon Nov 30, 2015 6:26 pm 
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Joined: Wed Jun 04, 2014 6:10 pm
Posts: 132
Location: San Luis Obispo, CA
How much would the additional battery packs weigh? (A very rough calculation estimates that the weight would be 495 lbs based on 36 kWh and 160 Wh/kg.) While I like the idea of additional range I am curious as to how the additional weight of the battery packs would affect the vehicle's handling/dynamics (acceleration and braking).

I think it would be great if sometime in the future the main battery pack could be upgraded with improved cells, but the chance of that is slim to none.

Also what would the cost of the additional battery packs be?


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