-
Apologies for the comedy wobbly camera skills, i was really converned not to drop my camera through the floor onto the road. Also i was concerned not to injure myself as i was bouncing along trying to fit my hand safely thru that sharp edged hole. Here is a video from quite some months ago, it was a short driving test to check there were no problems with the installation of the differential and the custom driveshafts to the rear wheels. There was yet no electric motor drive installed, you can see simply the input drive flange of the Mitsubishi Shogun differential. My main concern was to check that everything was spinning smoothing and without any unexpected noises. Also of concern was to check the re-installed ABS wheel speed sensors were working correctly, this was a big relief that i could retain the original sensors and keep the standard vehicle brake system ECU functions happy.

Comments

  1. UnknownMay 15, 2021 at 9:43 AM

    Brilliant! 😁

    ReplyDelete
  2. PeterJuly 6, 2021 at 12:46 AM

    Good stuff.
    I came across your post as I was actually searching for something like this. I think the concept makes a lot of sense, especially if the van is already offering in an AWD option, so an AWD rear axle can be used? Such as the Sprinter or VW 4Motion (Caravelle, Transport, Crafter etc).

    Anyway, I am looking forward to following this. /Peter

    ReplyDelete

Post a Comment

Thankyou for your interest in my blog, i appreciate genuine comments or questions which i will moderate based on their technical content and will repond to those.

Popular posts from this blog

Design of a spool and connection from the Twizy gearbox to the Pajero disconnect clutch.

-
Image
Hello, and a long overdue update. One of the key difficulties with this project is the necessity of a disconnect clutch between the electric motor and final drive. Ideally this should be as close to the wheel hubs as possible. In the absence yet of designing a whole new custom free-wheeling hubs beam axle, i decided on a solution with using a dog-clutch disconnect mounted immediately after the reduction gearbox and upstream of the Pajero differential. The hardware i found suitable is the freewheel disconnect part from the front axle of a Pajero-io 4WD SUV. This was suitable because the clutched axle part is a separate module from the front diff body. A similar design exists in the larger Pajero gen.3 model front axle, but on that one the clutch assembly part is integral with the axle differential body, so the clutch can not be removed by itself. So the design problem has contained three elements, 1/ how to connect the output from the Twizy/Comex gearbox to this Pajero clutch shaft, 2/
Read more

Design of driveshaft between clutch and axle.

-
Image
Designing the final connecting driveshaft after the clutch until the flange of the rear axle differential. It may or not be as simple as this sleeved coupler shown in this CAD model. This shaft located between a pair of CV-joints will be rotating all of the time being driven from the road wheels at approx x4.2 speed via the diff ratio. So it is important that it will be working without vibration. Given the design constraints of packaging the motor-gearbox and clutch under the chassis, providing sufficient ground clearance while avoiding too much butchery cutting through the vehicle floor or cross beams, i have tried my best to keep an acceptable drive shaft alignment. Noting that all the components are fixed to the vehicle floor/chassis, so suspended independent from direct or any relative motion with the road axle.
Read more
-
Image
Welcome and a brief look intro to my 'OffRoadHybridVan' project. The motivation for this project is to learn something practical of the engineering technology behind electrification of a vehicle. However deciding against, for many good reasons, not to attempt a full battery-EV conversion of my camper van, considering the size, weight, cost, limited range and charging demands which such a 3500kg vehicle would demand. This decision not to embark (at least not yet) on a fully 'green/zero-CO2' project van will likely be a disappointment for many readers. The reality is that most owners of these camper van and the van-life culture associated with them, despite our best dreams to the contrary, the cost of full EV conversion and the limitations incumbent with driving range and mobility(charging) would be a severe compromise to getting to and staying off-grid, by desire away from urbanity and decidely off-grid - by definition out of sight of any charge point. The ubiquitous ava
Read more