First-Gen RAV4 EV (1996-2003)

[graham]

In fact, we currently have a 1996 RAV4 EV conversion that can do 90 mph top speed and can drive 100 miles in range at 65 mph.

This sounds similar to me to the specs touted for the RAV4 EVs running on NiMH. Am I misremembering the stats for that? How do these new Li-ions compare?

[donauker]

He says 33kWh for the new Li-Ion conversion, and the old OEM Rav4EV NiMH was only 25kWh.

The specs (100 mile range ) seem similar, so was the older drive-train more efficient?

Since the old Rav4EV is long since off the market it is nice to have a replacement option for that type of vehicle.

TEG,
Was the old Rav4EV able to attain 100 mile range at 65 mph?
That would only be 250 Wh/mi. That is extremely efficient at 65 mph.

[TEG]

Toyota RAV4 EV - Wikipedia, the free encyclopedia

...a governed top speed of 78 mph...

...a range of 100 to 120 miles...

Rav4EV Data

...Driving range...125 miles

My range record (and I don't try for max range very often!) per charge was accomplished 08.21.05. I drove 133 miles on 100% SOC. Two people in the car, plus the portable charger in back. Twisty, hilly drive with many stops at the beginning and end. Heavy AC use for one full leg of the two-way trip. Final score: 191 Wh/mile consumed = 5.2 miles per KWh = range of 133 miles = 25.9kWh pack. (To calculate pack capacity: multiply kWh consumed by 100, and divide that by percentage of SOC consumed.

Average Consumption from pack: 250 Wh/mile

So, the above didn't exactly answer your question, Don. EVnut says 191 Wh/mile on his longest trip, but also says 250 Wh/mile average, so constant 65mph is likely somewhat less. Still I think the "over 100 mile range" is rather impressive given that the vehicle seats 4 and isn't particularly aero optimized.

My RangerEV has a similar NiMH pack but only does about 60 mile range due to less efficiency.

[James]

Did you notice that the factory RAV4 EV from Toyota doesn't have a tire hanging on the back? Also no roof rack.
Our testing shows that is worth 8% more range due to less drag.

Our 1996 RAV4 conversion and the 2009 RAV4 that we are working on, both have the tire on the back still and roof rack.
They look stupid without the tire because the rear was shaped to have the tire there. It looks naked without the roof rack.

There is more to it than merely the number of batteries inside.

Home Page

2009 RAV4 EV - a set on Flickr

Factory RAV4 EV


Ours that we have converted

[TEG]

In fact, we currently have a 1996 RAV4 EV conversion that can do 90 mph top speed and can drive 100 miles in range at 65 mph.

The battery pack that I am building for a 2009 RAV4 EV conversion is 33 kwh.
105 cells X 100 Ah each.
These are Sky Energy SE cells, which are actually better than Thundersky, but it is a newer company.

Actually as I re-read James' quote it seems he says they have a 1996 RAV4EV conversion that does 100 mile range @ 65 mph... *and* they are building a 2009 RAV4 EV conversion with 33 kwh... So, James, what pack capacity does the 1996 conversion have?

By the way, I noticed a RAV4EV Li-Ion retrofit project here:
Rav4ev

[TEG]

Also, James, do you do something with your battery box to physically constrain the cells. I think under different charge/discharge conditions the cells can try to change size/shape and if you don't put something rigid around them they can crack/rupture over time.

[James]

Actually as I re-read James' quote it seems he says they have a 1996 RAV4EV conversion that does 100 mile range @ 65 mph... *and* they are building a 2009 RAV4 EV conversion with 33 kwh... So, James, what pack capacity does the 1996 conversion have?

By the way, I noticed a RAV4EV Li-Ion retrofit project here:
Rav4ev

I forget the kwh size of the 1996 RAV4. My technician did that before I started working with him. That 1996 RAV4 is what got him credibility with me.

The 2009 RAV4 will likely have a 120+ mile range because we are doing an AC motor with regen.

The 1996 RAV4 conversion was a DC motor with no regen.

[James]

Also, James, do you do something with your battery box to physically constrain the cells. I think under different charge/discharge conditions the cells can try to change size/shape and if you don't put something rigid around them they can crack/rupture over time.

Yes. There are battery boxes to contain the LiFePO4 cells. I don't have all of the details, but they are contained.

[JRP3]

Which AC system are you using?

[James]

Which AC system are you using?

Azure Dynamics AC55. We bought a bunch of them unused from a company that went bankrupt.