[WIP] 1975 Barkas B1000 with Leaf-Motor and ID4 Inverter
Posted: Sun Aug 18, 2024 9:54 pm
Hello friends of the electric drive.
I discovered this forum while researching the Leaf motor and, like many others, would now like to present my personal project. I am fascinated by how many enthusiasts are out there who want to convert their own special vehicle. I would like to use the forum for inspiration and learn from other members' solutions for my own conversion.
About the project:
The vehicle is a Barkas B1000 built in 1975. These cars were built from 1961 in the former GDR in East Germany as fast transporters. My vehicle was a fire engine in its 1st life. I would like to equip the Barkas with an electric motor and drive it for the next 40 years
I want to use the Leaf EM57 motor. However, the inverter will probably be based on the ID4 front-wheel drive and will be mounted on the Leaf motor with an adapter plate. I would like to do this for the following reasons:
-The ID4 inverter already has an integrated EMC filter
-The power modules are currently still being produced and further developed and are available as IGBT and SiC variants
-The inverter uses 3 current sensors for the phase currents
The motor should not simply be flanged to the existing gearbox. I want to remove the differential from an existing Barkas gearbox and put it in a newly manufactured housing. The manual gearbox and clutch will therefore be removed. The gear ratio of the differential is 5.2857. The maximum speed of the engine is to be limited to 4500 rpm. This corresponds to around 100 km/h. The maximum torque should be around 300 Nm at the motor and I want to limit the maximum power to 40 kW. This means that the drive is 4kW above the maximum output of the original engine, but slightly below the maximum torque of 350 Nm in first gear.
My background:
I have a doctorate in engineering in the field of power electronics. I can design circuit boards and program microcontrollers. I also like classic cars and enjoy working on old machinery in my spare time. Like the Barkas I am from the East-part of Germany.
The timetable:
It should be legal on the road in 2027. That could certainly be achieved sooner, but with a house and two small children, it's a realistic compromise. I also want the vehicle to be exactly how I want it to be.
Current status:
The vehicle has been completely dismantled and the chassis and bodywork professionally blasted and primed. Repair work is currently being carried out on the bodywork. After that, I will continue with filling, sanding and painting. At the same time, I am developing the drive train. I have the motor and inverter on hand. I replace the driver board and the control board of the ID4 inverter with an own development. This will be followed by testing and measurement on the test bench.
I will report my progress and findings here from time to time.
Many thanks for your interest,
Florian
I discovered this forum while researching the Leaf motor and, like many others, would now like to present my personal project. I am fascinated by how many enthusiasts are out there who want to convert their own special vehicle. I would like to use the forum for inspiration and learn from other members' solutions for my own conversion.
About the project:
The vehicle is a Barkas B1000 built in 1975. These cars were built from 1961 in the former GDR in East Germany as fast transporters. My vehicle was a fire engine in its 1st life. I would like to equip the Barkas with an electric motor and drive it for the next 40 years
I want to use the Leaf EM57 motor. However, the inverter will probably be based on the ID4 front-wheel drive and will be mounted on the Leaf motor with an adapter plate. I would like to do this for the following reasons:
-The ID4 inverter already has an integrated EMC filter
-The power modules are currently still being produced and further developed and are available as IGBT and SiC variants
-The inverter uses 3 current sensors for the phase currents
The motor should not simply be flanged to the existing gearbox. I want to remove the differential from an existing Barkas gearbox and put it in a newly manufactured housing. The manual gearbox and clutch will therefore be removed. The gear ratio of the differential is 5.2857. The maximum speed of the engine is to be limited to 4500 rpm. This corresponds to around 100 km/h. The maximum torque should be around 300 Nm at the motor and I want to limit the maximum power to 40 kW. This means that the drive is 4kW above the maximum output of the original engine, but slightly below the maximum torque of 350 Nm in first gear.
My background:
I have a doctorate in engineering in the field of power electronics. I can design circuit boards and program microcontrollers. I also like classic cars and enjoy working on old machinery in my spare time. Like the Barkas I am from the East-part of Germany.
The timetable:
It should be legal on the road in 2027. That could certainly be achieved sooner, but with a house and two small children, it's a realistic compromise. I also want the vehicle to be exactly how I want it to be.
Current status:
The vehicle has been completely dismantled and the chassis and bodywork professionally blasted and primed. Repair work is currently being carried out on the bodywork. After that, I will continue with filling, sanding and painting. At the same time, I am developing the drive train. I have the motor and inverter on hand. I replace the driver board and the control board of the ID4 inverter with an own development. This will be followed by testing and measurement on the test bench.
I will report my progress and findings here from time to time.
Many thanks for your interest,
Florian