ECOSTAR DC50 (Tomcat) - CHASSIS DESIGN

A British sports car concept featuring the Bluebird FE cartridge exchange instant recharging system

 

 

KISS, is the acronym for 'keeping it simple silly.' We use these principles throughout the design and development process. Effectively, we are producing a custom built one off prototype for this project - the target for completion is around 8 months. Steel is used for the main space frame, welded at the moment (possible change to bolting) to sub-frames front and rear that carry proprietary running gear, such as to comply with the new Cannonball International rules. Adopting this method we do not have to spend our time re-inventing the running gear, where there are literally thousands of components made by hundreds of motor manufacturers - that are more than up to the job.

 

 

The Ecostar DC50 is a two seat sports city car that uses batteries to store energy, in cartridges - which, the vehicle can load and unload itself without the need for external assistance. The same cartridges can store energy as hydrogen for built in fuel cells. The design is simplicity personified. KISS. For this project we are using the tried and tested Agni dc electric motors (Cedric Lynch designed). Four units provide around 50kW, or 67 horsepower. This is electric horsepower, where the torque at standstill in the same as for a petrol engine at 2-3,000 rpm. The power to weight ratio is close on 100 hp/ton.

 

 

The challenge for the Ecostar DC50 is to reduce the long standing 1 minute recharging world record, to less that 30 seconds using a legacy design. The cartridge shown in these diagrams is not that proposed for the Bluebird™ universal cartridge system. But, it is a start and will provide us with the data we need to develop the system into a full blown energy network for cities such as New York, Paris and Rome. We hope to be able to implement a system locally in East Sussex, to include: Brighton, Eastbourne and Hastings - a coastal network. A town such as Eastbourne would be ideal to electrify, which might require only 5 service stations to completely eliminate the need for petrol service forecourts. It is fuel for thought.

 

 

 

The layout of the Ecostar DC50 (Project Tomcat) provides a near perfect weight distribution from a front wheel drive car. This is ideal for nipping around city streets, yet with racing car handling should you need it. The cartridge (in this case shown with batteries as the energy storage medium) is low, keeping the center of gravity well below that for conventional sports cars. In this Autocad diagram, you can see the built in electrically powered loading mechanism in turquoise. Click on the picture to read more about the mechanics of this car and how we aim to cut charging time around 30 seconds without frying batteries. With a flatpack loading design, the boot space is not affected - what little is available with any sports car body.

 

 


Putting all of that into practice is another matter. The donor frame needed a lot of work cleaning and upgrading the welds. The new low seating position worked in theory in Autocad, but needed to be proven - and what better way than to have two of the project team, in this case Chris (project leader) and Terry rig up some test seats, while welding in the floor-pan frames as per the Autocad design. The great thing about working this way is that time from the drawing board to the road is considerably shortened. Snagging feedback to the computer design goes straight back from the workshop.

 

 


LEFT: The project leader, Chris, makes sure that the steering position will be comfortable. RIGHT: Terry, adopts a more relaxed attitude, confident that the design will work. The seats will be custom made for comfort and to keep the weight low. Both men were hard at work cutting steel and welding the fabrications into position. So far so good. This is April 2014. The Ecostar team need to have the new cartridge loading mechanism ready before December if they are to be ready for the Lands End to John o'Groats Cannonball ZEV Run in 2015. They are hoping to have the bodywork well under way by June 2014. Gull wing doors are a possibility.

 

 


Positional welding is very demanding. Where the Ecostar is so light, it is possible to flip that car onto its side - and even turn the frame upside down to help the team obtain as near perfect welds as possible. Click on the picture above to see the welding sequences.

 

 

battery cartridge electric servo mechanism front

battery cartridge electric servo loading mechanism rear

Picture of the flat electric loaders that lifted a cartridge into place in around 60 seconds - battery cartridge is seen below.

Rear end or car (boot) showing the same loaders fitted so as not to impact on boot space.

   

 

ECOSTAR DC50 EV CHASSIS FEATURES

 

BODYWORK

Composite

.

.

FRAME

High tensile steel

.

.

CARTRIDGE

.

.

.

OVERALL LENGTH

 mm

OVERALL WIDTH

 mm

OVERALL HEIGHT

 mm 

.

.

ENERGY CAPACITY

.

.

.

LITHIUM

kW

FUEL CELLS

kW

.

.

EXCHANGE TIMES

.

.

.

LITHIUM

Target 30 seconds

FUEL CELLS

Target 30 seconds

 

 

Horizon 2020 transport research and innovation ideas

 

HORIZON 2020 - TRANSPORT RESEARCH & INNOVATION

 

The main aims for Horizon 2020 are:

 

1. Making transport more sustainable: resource-efficient transport that respects the environment.


2. Making transport and transport systems seamless: better mobility, less congestion, greater safety and security.

3. Keeping transport competitive: the European transport industry as a global leader.

4. Making transport research responsive: socio-economic research and forward-looking activities for policy-making.

We hope to be able to find manufacturing partners to be able to take whatever comes out of this project to the next level. We are not sponsored at this time.

 

HOW?

 

Most production vehicles built today are suitable for conversion to the Bluebird™ Universal cartridge exchange system. Thus, with a fair wind the system may be described as "universal."

 

The only way we'll ever be in a position to qualify our initial assessment is to convert all of the popular vehicle formats: hatchback, estate, coupe, SUV or PSV, etc.

 

A simple survey of any proposed model will confirm suitability and highlight any potential problems. You can see how simple the basic design is. A truly universal cartridge will be lower in height and wider.

 

The reason we are developing this particular vehicle is that we are not state funded. We are a micro enterprise and as such with no trading record, we do not have access to finance for such high risk ventures.

 

Motor manufacturers or Energy companies who might be interested in exploring the possibility of collaborating on this valuable research are invited to contact Chris in confidence. We are more than willing to operate under the cover of a NDA.

 

 

BE1 battery cartridge exchange chassis framework blue bird electric 1

 

This was the first ever electric vehicle chassis to incorporate built in cartridge loaders. We now own this historic vehicle. It was was built by one man, by hand in around 4 months. The completed car was featured in the Daily Telegraph, displayed at Beaulieu in the Land Speed Record hall of fame, at the London Arena, Olympia and featured on the Big Breakfast with Keith (Cheggers) Chegwin, who managed to sit inside what is a very compact head first position. The car achieved 160mph on a stretch of road between Polegate and Pevensey in East Sussex that had not been opened to the public.

 

 

 

ECOSTAR DC50 LINKS A-Z INDEX

 

 

 

 

 

 

 

EXTERNAL LINKS

 

http://www.horizonhydrogeneenergie.com/

http://www.fch-ju.eu/news/new-website-programme-horizon-hydrog%C3%A8ne-energie-h2e

http://www.fch-ju.eu/

http://horizon2020projects.com/sc-transport-interviews/storing-energy-in-horizon-2020/

http://horizon2020projects.com/sc-transport-interviews/powering-the-future/

http://cordis.europa.eu/fp7/ideas

http://ec.europa.eu/programmes/horizon2020/en/

http://ec.europa.eu/transport/themes/research/horizon2020_en.htm

http://www.agnimotors.com/site/

http://www.engadget.com/2012/11/13/mclaren-to-supply-ev-groundwork-for-formula-e-cars/
http://ibnlive.in.com/news/bernie-ecclestone-laughs-off-formula-e-comparisons/302635-5-24.html

http://www.wired.com/autopia/2012/09/formula-e/

http://www.telegraph.co.uk/finance/The-electric-cars-of-the-future.html

http://www.greencardesign.com/site/galleries/racing-drayson-b1269ev

 

 

Tomcat original electric sports car

 

This is the original Tomcat electric concept car from April of 1995, drawn in Autocad while the original designer was at Brighton College doing a City & Guilds crash course in computer aided draughting and design. In the top left hand corner you can see that upright pneumatic cylinder loaders were incorporated as specified for the BE1 some time earlier. On the right where a rear IC engine might be fitted, is a 5kW generator - making this a hybrid vehicle. The battery cartridge is taller and slimmer than the DC50 chassis above, but is located longitudinally in the vehicles central tunnel in much the same way.

 

 

 

 

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