DIY EV Hardware
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The Mark Hanson Collection DIY EV Hardware |
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The circuits below were designed by electrical engineer Mark Hanson. He's used most of them with his EVs. A few
are related projects for renewable energy systems which may be used to charge EVs. A few are unrelated to EVs,
but are included here just for their fun, information, and/or utility. Mark is releasing these designs into the public domain for the good of the EV cause. Please note however that these aren't cookbook instructions. Using them calls for some electronics expertise on your part. You'll have to adapt the design for your particular situation, lay out and fabricate a circuit board, figure out how to mount components, design a housing, etc. For circuit board design, Mark recommends Express PCB free schematic drawing and layout software. All the projects that use microcontrollers were done with the Mon08 programmer and development system from P&E Micro. If you don't want to write your own code, Mark will supply programmed MC68HC908QY4 microcontrollers for $20 each. Write to Mark E. Hanson, 184 Vista Lane, Fincastle, VA 24090 or email him at More information on these designs is available at Mark's website, Selectrol Electronics. |
| EV Projects | |
| Mark's most recent DC motor controller, as used in his E-Porsche (firmware source here) | |
| Small PWM controller for variable fan speed and accessories in EV | |
| Charger using microwave oven transformer (version for 84v battery) | |
| Charger for the solar electric boat Jerry Dycus and Mark built (similar to above, but for 48v battery) | |
| Mark Hanson's DIY DC:DC converter as used in his Bombardier | |
| Lee Hart's battery regulator - schematic by Mark | |
| Lithium Ion battery charge equalizer (last revised April 2012) | |
| Battery scanner individually and simultaneously monitors up to 24 batteries in an EV's pack | |
| Water level detector for basement or bilge flashes LED faster as level rises - also can sense electrolyte level in batteries with carbon or stainless probes | |
| DC Watt-hour counter tracks EV battery level, or RE system energy production | |
| Inverter converts 24-72vdc to about 1400 watts of 120v or 240v 60Hz AC, for EV air-con and other accessories | |
| Adapter converts existing ICE tachometer to work with EV, using Hall pickup and magnets | |
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Flipflop connects in line with NEV's Hall speed sensor to raise governed speed to 45mph. (Caution: make sure brakes and steering suit the higher speed!) |
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| EV Power Control (as used in Mark's Ghia) - precharge, emergency disconnect, heater control, high pedal startup lockout, full pedal controller bypass | |
| Addenda to above (as used in Mark's Porsche), with ground fault detector | |
| Chevrolet Bolt EV Trailer Light Schematic | |
| Tesla Y Trailer Light Schematic | |
| Renewable Energy Projects | |
| Booster-regulator charges a 24v battery from the variable 8v-30v output of a wind machine | |
| Small PWM controller for a woodstove fan | |
| Solar differential thermostat | |
| Two-axis solar tracker | |
| Switch on outside light to partly discharge PV battery to 90% SOC, for next day's solar collection | |
| Log Annunciator - monitors woodstove temperature and controls fan. When the fire burns down to one log, it plays Shel Silverstein's tune Put Another Log On The Fire | |
| General Projects | |
| General purpose buck converter - input 25-30v, output 18v 3a / 12v 250ma / 5v 250ma | |
| Four oscillator designs based on crystal, capacitor, and ceramic resonator references | |
| Pink noise generator to mask ambient noise for a good night's sleep | |
| Stabilizer cleans up DVDs with sync scrambling copy protection (not intended for illegal use) | |
| Muscle Feedback Monitor demonstrates principle of EMG (electromyography) biofeedback devices used by stroke victims, measures voltage in microvolts produced by the brain across a muscle (updated 30 Dec 2010) | zip |