wh per km with SLA batteries

egokart

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Hi all

I've got a 36v 800w motor from Alfa Wheels with a 800w controller. It's going on a standard asphalt junior track racing kart chassis, intended for a bit of fun for 11-13 year old kids. So, 30-40kg passengers. I'm guessing at max 70kg all-in weight, kart and driver. Do these numbers look reasonable?

- 7AH x 3 x 12v SLA batteries (AGM type)
- 50wh per km at average speed of 20km/h, 30 degrees C ambient
- max range at 60% DOD = (7AH x 3 batteries x 40% x 12v)/50wh = 2km

Cheers, thanks in advance.
 

itsid

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6min runtime sounds reasonable yes,
not sure 70kg is alright tbh..
I never actually weight my kart either, but I think it's closer to 50 kg than 30.
minus the enigne, plus motor and batteries... I'd say it'd stay in that realm.

7AH batteries are a bit on the weak side, since you're requesting somewhat around 30Amp peak,
and that' be a discharge rate of 4-5C causing a significant loss of max capacitity
(45% or less I'd assume)
So yeah roundabout 6 minutes runtime.
but that's not 60%DOD, that's fully drained (hitting the controllers undervoltage protection)
the batpack is likely to recover if allowed to rest for about an hour to maybe gain another two minutes perhaps.

But no hijacking please
•SPLIT•

I wonder how you concluded the 50Wh.. that IMHO is a result of a miscalculation tbh,
since I don't think that's in any way or form a reasonable value.

The battery has a total capacity of 7Ah the final 36V batback therefor has a capacity of 252Wh
draining that in 6mins means more like 2.52kWh (to be fair only 45% of it is actually used..)
still 1.134 kWh used for ~2km to me that's more like 567 Wh/km ;)

'sid
 

egokart

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I'm hoping for around 100 cycles at 100% capacity on 12v 7AH SLA batteries.

I'll be using a 12T motor sprocket and 72T axle sprocket. I haven't gotten to figuring out what the draw would be for a 70kg kart with a 1:6 ratio.

I took the 50wh/km from this guy's thesis here's an excerpt:

The average power of the entire system and
the electric motor were found to be 5.95 kW and 5.4 kW, respectively. The total energy consumed for
this electric traction drive system was 56.61 Wh in one lap with the regenerative braking energy and
920 Wh in the whole race. The average stator current in the induction motor was 75 A and this current
was below the rated one.


His calc was for a much faster kart, so I feel 50wh/km is very conservative in the case of this kiddie kart. I'd expect a Tesla to get near 100wh/km if it did slow laps of a go kart track :auto:

Checking my own calc: 600w continuous motor output x 0.1 hours = 60 wh required to run it for 6 minutes. If I have 100wh available, 10 minutes should be doable.

I got the max current draw on the 12v 7AH from here, which states 21A for 7 minutes. If the motor was at 600w continuous, 600w/36v = 16A.


The battery has a total capacity of 7Ah the final 36V batback therefor has a capacity of 252Wh
draining that in 6mins means more like 2.52kWh (to be fair only 45% of it is actually used..)
still 1.134 kWh used for ~2km to me that's more like 567 Wh/km


I think that should read:

252 wh x 45% = 113.4wh is available. So at 50wh/km, I should be able to do 2km and stay above 55% DOD.

Just weighed the kart:

Unit Total Pieces
kg kg

Chassis 26
Tyres Front 1.3 2.6 2
Back 1.8 3.6 2
7Ah cells 2.65 7.95 3
Motor 4
Kerb weight 44.15

Human 30
Gross weight 74.15
 

itsid

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I took the 50wh/km from this guy's thesis here's an excerpt:
...

His calc was for a much faster kart, so I feel 50wh/km is very conservative in the case of this kiddie kart. I'd expect a Tesla to get near 100wh/km if it did slow laps of a go kart track :auto:
Without reading the whole paper for now...

And for a single lap on his göteborg race track not a km but a lap;
lap duration is 48s with about 12seconds in regenerative braking mode
and another 10-12 seconds of coasting along
(eyeballed from figure 3.4)

So maybe 25 seconds of load

Now, since you take ~ 3mins per km as per the calculatio above,
and we talk 56.6-ish Wh in 25 seconds of throttle down
(in case you want to stick with that example)
the multiplication factor would be 7.2 (180/25)
7.2*56.6 means 407Wh per km

Now, the gain from regenerative braking is already factored in in his 56.6Wh (w/o regen braking he used 67.9Wh per lap [figure 6.1])
And since I don't assume you have regen braking
that is what we would want to look at
7.2 * 67.9 -> 489Wh per km

Now, motor power is not necessarily a part of that equation mind you,
speed is, acceleration is, weight is, coefficients are..
but motor power is NOT..
it only affects how much acceleration you can achieve and what speed you're able to reach (and thus reduce time)
but since you converted that to distance travelled, speed is
effectively cancelled out.

You can run a 5kW motor and draw less than 800W mechanical from it easily.
So the difference between it and your 800W motor is just the weight and the efficiency difference between the two systems.

If you want to look at it the other way around...
his min calculated battery was 19.2Ah and in a 48V setup
(920Wh) to be drained in one race (13min)
putting the setup in the realms of 4246W of average powerdraw
And while you certainly cannot draw as much with your 800W motor,
that also means you cannot reach the 90km/h he peaked at, and certainly not accelerate as quickly.. sooo your total lap time would certainly increase,
but it's not totally impossible that your battery would have to be about the same size to finish the same race (in longer time at slower speeds but traveling the exact same distance on the exact same track)


Aaanyways...
NO you mess up a few minor things that will bite you later on.

first: 600W mechanical power out IS NOT 600Watt power drawn from the battery!
(system efficiency... 'he' gained an overall efficiency of 66.7% with his setup for example)
if we assume the same overall efficiency for your setup 600W of mechanical power on average on the rear wheels means 900 Watts of power drawn from the battery.

second: The Ah rating of your battery is NOT a fixed value,
it is what you can trickle from said battery at a much lower than 1C rating.
once you crank up the amperage the useable amount of stored energy is MUCH lower (as I said @4C I assume about 45% means ~3.2Ah in your battery not more)
that's only a guestimated value of course, if you have the proper battery documentation you can derive the actual values from there.

once you've drawn those 3.2Ah of energy, the battery is FULLY depleted
So DOD SOC and all that technical babble becomes 100% obsolete
since while nominally you only used 45% the battery still is in a 100% cycle (well actually -as I mentioned- it'll recover slightly.. so say 85-90%)
You will NOT stay above 55% SOC in fact you will drop below 10%,
once the cells are allowed to cool down it then again might rise back to 15% (in best case scenario) but that's it..
[Oh I think you got Depth of discharge and state of charge the wrong way around..
SOC 0% is an empty battery, and SOC 100% is a full battery.
DOD 0% is a FULL battery, and DOD 100% is an empty battery.
nevermind]

And these two things get you over and over again..
power draw (as stated above) might be as high as 900VA for your 600W estimate means 25Amps
and at peak power (pedal to the metal uphills) migth easily crack the 30Amp mark in drawn currents.
which again reduces the available [or rather useable] capacity of your battery.
that effect is also escalated by the low voltage cutoff of the controller btw..
(a 36V controller usually cuts power @32Volts at least to keep lead acid cells rechargeable.. and that means there's always a not too insignificant left over charge in your battery)

if you want a guaranteed 10min runtime..
all I can suggest is to scale up the batteries to 11Ah
that at a assumed max current of 33A would equate to 3C and an easier go on the battery.. a theoretical runtime of 20mins
and with a maybe 65% useable capacity @3c gives you 13mins;
the 3min overhead gives you a remaining SOC that should be enough to keep the cell at 10.5V and thus rechargeable.

And yes, going easier on the pedal increases ride time...
but that wouldn't be too bad, would it ;)

Oh 75kg roughly.. good
let's check with some math
64N @5.55 m/s means about 360watts mechanical
to keep the kart at speed on a slight incline.
less than 200 on level road
and maybe 300 to accelerate decently.

nice!
so the 800W motor never really needs to provide half it's nominal power; great.
Indeed the 7Ah batteries might do the trick then.
Sure one can accelerate quicker and climb steeper hills and all that to
reach it's limits, but ordinarily that's not exactly necessary in that setup on 'normal' western roads.

If you have 7Ah batteries alread.. it's worth a try I'd say
(with 14Amps peak current it might be able to peak at a 24min runtime then if I'm not mistaking)

'sid
 

egokart

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Acceleration calc - I do hope I'm wrong

Thanks 'sid, much appreciated.

I've attached a calc for acceleration on flat smooth concrete. Clearly rolling resistance will be a bigger issue than drag with this kart, I haven't taken that into account because I'm already miserable at the slowness:ack2: - I hope it's wrong.
 

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itsid

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Well you miscalculated m/s and km/h somehow
it's a 3.6 factor between the two and nothing but
(3600 seconds per hour, 1000 meters per kilometer 3600/1000 = 3.6
thus 5.5555p m/s *3.6 = 20km/h)

so your spreadsheet should read
20.23 km/h for the 12T sprocket and
23.6 km/h for the 14T sprocket

and I kinda hiccup on the "time to reach speed in m/s" in your spreadsheet
I can't seem to id any of those values to put them into perspective.

Anyways.. here's what I tend to do
(I'll focus on the 12T sprocket since 20km/h was your target speed and more torque is more better :D)

first assume a minimum (wanted) acceleration of 1m/s²
and use the that together with the total weight and the driven wheel radius
to calculate the minimum torque required to accelerate the kart at that rate.
75kg * 0.115m * 1m/s² = 8.625 Nm

Now first hurdle is of course to get a motor/transmission torque that's higher than that number.
(checked ;))
and then we can get an idea of the max acceleration that system will be able to achieve,
simply by dividing transmission torque by said baseic counter torque
(or logically easier to understand.. increase the acceleration until the two match up)

So 16.68 / 8.625 = ~1.934
means we can accelerate with 1.934m/s with our available torque
(same math as above but quicker: 75*0.115*1.934 = 16.68075.. see?)
with that max acceleration the time to reach top speed
would be 5.62m/s / 1.934m/s² = 1.905s roughly

the torque drops with increased rpm and so will acceleration but it's at least a good hint
if we assume the torque to drop by 30% per second roughly,
the kart would still need less than 5 seconds to reach 20 km/h
the exact torque curve would tell us how long exactly if we would need to know ;)

'sid
 
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