Converting an MPV

[nuke11]

This is my idea on how to convert an MPV to fusion. No cutting of the vehicle or changing the general interior space required.

General ideas of how it is done, more specifics can be done if required.

The fuel tank is removed, but that same space can be used for a water tank instead for the crew.

An example of how an MPV might be converted;

- The diesel or gasoline engine, with the muffler, catalytic converter, tailpipe and gas tank are removed.
- A fusion power pack is added.
- The clutch assembly is removed. The existing manual transmission can be left in place, and pinned in second gear or a longer drive shaft is used.
- A new AC or DC electric motor is bolted to the transmission with an adapter plate or directly to the longer drive shaft with an adapter
- An electric controller is added to control the AC or DC motor. Example a 50kW controller uses 300 volts DC and produces 240 volts AC, three-phase.
- Electric motors are added to power things that used to get their power from the engine: the water pump (used to cool the electric motor if water cooled), power steering pump, air conditioner.
- A vacuum pump is added for the power brakes (which used engine vacuum when the vehicle had an engine).
- A small electric water heater is added to provide heat.
- The automatic transmission shifter is used to select forward and reverse. It contains a small switch, which sends a signal to the controller.

Everything else is stock. When you get in, you put the key in the ignition and turn it to the "on" position to turn the vehicle on or push a button to start or stop. You shift into "Drive" with the shifter, push on the accelerator pedal and go. It performs like a normal gasoline car.

When you push on the gas pedal, a cable from the pedal connects to two potentiometers: The potentiometers hook to the gas pedal and send a signal to the controller. The signal from the potentiometers tells the controller how much power to deliver to the electric motor. There are two potentiometers for safety sake. The controller reads both potentiometers and makes sure that their signals are equal. If they are not, then the controller does not operate. This arrangement guards against a situation where a potentiometer fails in the full-on position.