This was a busy week, with a full house of Bugeyes needing various repairs and restoration work. Our electric project is still a priority, and we made time to add a new radiator to our prototype electric car. This one is tiny, all it has to do is cool the controller, the brain that manages the batteries and motor.
I know that the Bugeye Sprite is all about simplicity, and an electronic brain is exactly the antithesis of what the Bugeye is all about. But until further notice, I am hooked on the smooth and maintenance free/turn-key operation of an electric Bugeye. In addition, of the 19 Bugeyes in our building at the moment, the electric is by far the fastest of the bunch. So if we need to add a little cooling to keep the brains of the operation happy, I am more than willing to comply.
I thought you might find this story interesting, as it represents one more way in which we had to engineer a solution to a British car challenge. It turns out that the controller is smart enough to de-rate the power it will transmit to the motor if it gets too hot. You can still limp home, but you don’t get the full power that makes this vehicle so addictive. We set out to fix the problem once and for all so we added a liquid cooled chill plate under the controller.
The silver plate you see in the photo above sandwiches underneath the controller box. You can see the recesses that will carry the antifreeze under the aluminum case that houses the controller. The square O ring around the perimeter keeps the antifreeze in place. Two half inch hoses and a small pump allow the antifreeze to circulate to a small heat exchanger we fit alongside the batteries.
Now, the controller will stay much cooler, which will allow us to send more power to the rear wheels. And thus our car is almost ready for range testing. If the weather improves, we will be out driving the car throughout the balance of the month.