Untitled - ev-bg.com

218 Build Your Own Electric Vehiclethe roadway through a “metering-box” in your vehicle (so the utility company knowswho and how much to charge), and you get recharged on your way to your destinationwithout all the pollution, noise, soot, and odors.If the roadway and your EV are both of the “smart” design, you can even get travelerinformation (weather, directions, etc.) while the roadway guides your vehicle in ahands-off mode, and you read the morning newspaper or scan the evening TV news.All it takes is infrastructure development—read that as M-O-N-E-Y.Your EV’s Electrical SystemTo say that the electrical system of an EV is its most important part is not an oxymoron—far from it. The idea is to leave as much of the internal combustion vehicle instrumentationwiring as you need intact, and to carefully add the high-voltage, high-current wiringrequired by your EV conversion.Do a great job on your EV conversion’s high-voltage, high-current wiring and itwill reward you with years of trouble-free service. Do it in a sloppy manner and,aside from the obvious boom or poof (accompanied by smoke), you open yourself toa world of strange malfunctions. The hidden beauty of any home-built EV conversionis that there are only two places to lay blame if anything has gone wrong: look in themirror and under the hood.This section will cover the electrical system that interconnects the motor, controller,batteries, and charger along with its key high-voltage, high-current power, and lowvoltage,low-current instrumentation components. Figure 9-7 shows you the system ata glance. We’ll look at the components that go into high-current and low-current sideseparately, then discuss wiring it all together.High-Voltage, High-Current Power SystemThe heavier lines of Figure 9-7 denote the high-current connections. When you put themotor, controller, battery, and charger together in your vehicle, you need contactor(s),Fi g u r e 9-7 Electric vehicle basic wiring diagram.