FuelTech has released its latest software, version 5.1, for its PowerFT VCU line and the biggest highlight is its Electrification Pack.
The just-released software brings the FuelTech products into the world of electrification, including hybrid drive systems. The software upgrade is compatible with FT600, FT550, and FT450 VCUs.
FuelTech and Electric Vehicles: the future is now!
Discover our electrification division
Electric mobility is already part of this era. We at FuelTech are proud to share with you the innovative work that we have expanded over the years: research, partnerships and development of new solutions for hybrid and electric vehicles.
On this page you will learn about FuelTech's advances in electrification, projects for converting combustion vehicles to fully electric or even in hybrid configuration, where the electric assists the performance of a combustion engine. Hard work of thousands of hours in research, development and testing, collecting information for the creation of a wide portfolio of products, news that will be available soon on the market.
The current PowerFT line was part of the development of electrification, and with it ECUs became VCUs (Vehicle Control Unit). In addition to managing the combustion engine, they can also manage the electric motor and several other important functions for the vehicle, such as: torque and power control of the electric motor, independent temperature and cooling controls of the electric and combustion systems, control of battery limits, energy regeneration and recharge, and mainly interconnecting all the vehicle's peripherals, generating better safety and performance in the application.
CONVERSION TIPS:
Here you will find some valuable information and tips for the electric conversion of a vehicle originally designed for combustion engines. However, before we focus on tips for electrification, let's get to know some elements that are part of the electrified system.
COMPONENTS AND FEATURES:
VCU: The control system of the electrified vehicle. FuelTech VCU’s have been updated to control the electrified system providing maximum performance, drivability and safety in all applications. The PowerFT and Vision FT lines are compatible with the most popular inverters, BMS’s, DC-DC converters and onboard chargers on the market, in addition to drivability, safety and diagnostic features.
Powertrain: This is the drivetrain of the electric vehicle. The electric motor and inverter has its own characteristics of power, torque and operation.
Battery pack: The bank of batteries which feed the electrified system. The choice of “pack” will determine the autonomy of the vehicle as well as guarantee the performance, power and torque of the powertrain.
BMS: “Battery Management System” is the electronic system responsible for monitoring the lithium batteries by reading the voltage and temperature of the cells. The BMS is also responsible for balancing the cells and for indicating to the systems the limit of electric current that can be charged or consumed from the battery.
PDU: “Power Distribution Unit” is the unit that distributes power from the high voltage battery to the system's components.
Power cables: These are electrical wires with adequate insulation, which interconnect the high voltage system.
DC-DC Converter: Is responsible for converting the high voltage of the vehicle's traction battery into low voltage for traditional 12V batteries.
On-Board Charger: Equipment intended for charging the traction battery, it is called OBC (On Board Charger), and converts the alternating current from the charging station into direct current which is then stored in the high-voltage battery.
Charging socket: Location where the battery charger socket will be inserted. There are several models, the most common being Type 2.
Transmission: Composed of the gearbox and clutch mechanism of the vehicle that will be connected to the electric motor.
Switch Panel FuelTech: It is an optional accessory, but extremely useful in adaptations. The panel has buttons that activate various actions of the electrified system and/or the vehicle, communicating with the FuelTech VCU’s via the CAN network.
Cooling pump: Electric pump used to circulate coolant in the Powertrain (engine and inverter), battery and sometimes chargers. The system requires a reservoir and the radiator, usually kept within the vehicle.
Vacuum pump: Electric pump responsible for generating vacuum for the brake booster (compensating for the vacuum previously created by the combustion engine).
- Keep in mind your goals, objectives, needs and the use that will be imposed on the electrified vehicle. This will facilitate the choice of powertrain and components. It is also essential to have an idea of the available budget, technical analysis and inherent viability to the project.
- Electric motors, by inherent characteristic, deliver maximum torque almost immediately at low rotations, it is a notable advantage when compared to a combustion engine. The combination with FuelTech VCU’s will guarantee the vehicle's performance, perfect drivability and safety. The choice of VCU will depend on the number of sensors, actuators and CAN peripherals required for each project.
- When choosing the Powertrain, look for a power and torque configuration that is close to the combustion engine that originally equipped the vehicle. This measure is a good practice in adaptation so that the vehicle has a similar approximate performance in relation to the original vehicle and guarantees safety when braking.
- Evaluate in advance the dimensions of the powertrain and the space reserved for it in the compartment where it will be installed. This will make it easy for the conversion to be accurate and fast, without requiring too many changes. Calculating and measuring spaces for the engine, transmission and batteries in advance will certainly provide positive results to the project.
- Each powertrain has a voltage level that requires a specific peripheral package (BMS, DCDC, OBC).
- Appropriately choose the set of batteries for the powertrain, checking your objectives between autonomy and performance.
- Lead cell batteries tend to have a lower discharge rate when compared to lithium and are much heavier, impacting the vehicle's performance and autonomy. As an advantage, the lead cell battery does not require a BMS or special charger.
- Some lithium batteries already come equipped with the BMS and power distribution unit (PDU) circuits.
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For the conversion, in addition to the engine, remove all components that are part of the combustion engine system, such as the fuel tank, fuel line, ignition coils and the electrical harnesses dedicated to the combustion engine system.
- Try to maintain the original position of the transmission system. This will facilitate the geometry of the axles and half axles connected to the transmission, as well as their movements in the suspension.
- It will be necessary to fabricate parts specifically designed for the conversion. For example; the connection flange for the new electric motor to be coupled to the transmission, supports for the electric motor, supports for the inverter, and the construction of safe housing for the batteries.
- When coupling the electric motor to the transmission, always respect the dimensions and original coupling parameters of the combustion system.
- The electrified system is capable of operating with various accessories such as air conditioning, power steering and the brake system vacuum pump. In these cases it is best to opt for the air conditioning compressor, vacuum pump and steering assistance system which are also electric, as this will benefit the entire process of conversion and facilitate the control of the system carried out by FuelTech VCU's.
- The making of the electric harness follows norms and standards necessary to supply the system power supply and maintain safety. Never underestimate or use components, accessories, or run the wiring harness outside the factory specifications and recommendations for each component. In addition to the necessary technical support, FuelTech has ready-made harnesses and you can purchase them from our website.
- Cooling the electric motor, and in some cases the batteries, is extremely important. Most of the time, the original combustion engine’s cooling system is capable of providing the necessary temperature change. In any case, consult the technical department to find out if your system is suitable and also about the settings for maintaining the temperature of the electric motor, as well as the batteries temperature specifications.
- Hybrid designs are also possible with FuelTech VCU’s combining combustion engines and electric motors.
- Each project requires different parameters, configurations, systems, peripherals and accessories. Whenever there is a doubt, look to our technical department.
- Always respect the safety standards required and certified NFPA 70E, a standard aimed at the health and safety of workers who interact in the installations and service of electrified vehicles.
- Never execute the project without appropriate tools and/or technical knowledge. There are specific tools and PPE for working with high voltage
