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Old 03-08-2011, 08:46 PM   #1
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Default 4T60E Control for High Power Conversion

Help.

I'm looking to start a high performance EV conversion (I'm aiming for 0-60 in under 5.5 seconds for a '96 Bonneville SE). I would like to keep the transmission (minus the torque converter) to at least keep some bare functionality at highway speeds as well. Seeing as the Engine will be long gone, the ECU and transmission control won't work much anyway, thus I plan on building my own Transmission control computer. I'm having difficulty, however, finding a decent wiring diagram so I can begin considering the controller. Does anyone know where I can find this information?

Thanks
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Old 03-08-2011, 08:49 PM   #2
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Old 03-08-2011, 10:19 PM   #3
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I've done a good bit of research on EVs. From what I understand, the hardest part about an EV conversion is the planning. It takes an immense knowledge your vehicle and how all other components (besides the gasoline engine work). I started researching here:

http://www.evconvert.com/faq

If you decide to use your automatic transmission, you will need a controller for it. I recommend a Megashift kit. Buy a GPIO board and the Megashift components. There is code for the controller to run a 4L60E, and I'm pretty sure it will run a 4T60E.
http://www.diyautotune.com/catalog/g...8740a1a440cf46

HOWEVER, I do not recommend you use an automatic transmission at all! It is simply unnecessary. It is much simpler to install a manual trans, set it in second gear and forget it. There is no need for a clutch and no need to change gears.

I wanted to do a DC motor even though I've heard that AC motors are more efficient and powerful. Here'* a good resource for EV conversion parts (including the controller).

http://www.electroauto.com/catalog/catalog.shtml

If you have any other questions, feel free to ask. I've done a lot of research on EV conversions and could probably point you in the right direction.
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Old 03-08-2011, 11:46 PM   #4
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I could go with a manual, but it wouldn't give me the exactly what I want. I plan on building a custom controller for the transmission and drive system, that allows quick smooth shifting, as well as explosive power. The higher gears are important though at high speeds. By removing the torque converter, my automatic would essentially operate as a manual anyway. I've narrowed down my motor selection to a handful of similar models. The benefit of DC is impulse power, even if at the cost of some efficiency. I don't need 60 mile range, I'd prefer the power. Being an electrical engineer by trade, I think the controller would be an interesting and fun project. Of course, being convinced I can build a better motor controller than what is available on the market for thousands of dollars (who said ego wasn't involved?), I think I can pull it off. I could go for a a smaller, lighter manual car, but that isn't what I'm after. Being able to smoke a Boxster off the line? That'* more my cup of tea.
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Old 03-08-2011, 11:49 PM   #5
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This is a project I would love to follow. Be sure to start a thread when you start the project and post up lots of pictures.
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Old 03-09-2011, 12:20 AM   #6
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Quote:
Originally Posted by sonnday View Post
I could go with a manual, but it wouldn't give me the exactly what I want. I plan on building a custom controller for the transmission and drive system, that allows quick smooth shifting, as well as explosive power. The higher gears are important though at high speeds. By removing the torque converter, my automatic would essentially operate as a manual anyway. I've narrowed down my motor selection to a handful of similar models. The benefit of DC is impulse power, even if at the cost of some efficiency. I don't need 60 mile range, I'd prefer the power. Being an electrical engineer by trade, I think the controller would be an interesting and fun project. Of course, being convinced I can build a better motor controller than what is available on the market for thousands of dollars (who said ego wasn't involved?), I think I can pull it off. I could go for a a smaller, lighter manual car, but that isn't what I'm after. Being able to smoke a Boxster off the line? That'* more my cup of tea.
You must have seen the White Zombie video'* on youtube hahaa!

I'm very VERY interested in your build if you get to it. Make sure to make a thread here for us to follow. Let me know if you go with the Megashift because I've considered building one for myself to use with a 4t60E.
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Old 03-09-2011, 07:30 AM   #7
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Happened to see this the other day. Not sure if it'll help or if I'm too late at this point.
http://e-transcontrol.com/
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Old 03-09-2011, 08:31 AM   #8
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ive been thinking about doing this to my monte lately, not for power for commuting duties and would be interested in your project.

ive also got to figure out a way around the obd2 emissions inspection for this stupid state of NY.
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Old 03-09-2011, 08:54 PM   #9
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I'll be sure to post pictures once I begin. As JONPRO03 said, the planning is the hardest part.

The e-transcontrol looks interesting, and is the closest to something I think is workable I've seen. My after going through the manual some (thanks DANTHURS) the control is not so complicated. My biggest worry is the lack of torque converter. Any sudden shifts I imagine the transmission can take, but with a direct lock between my electric motors (plural) and the input to the transmission, the armatures of the motors will also be subject to that shock, which will also reverberated through the drive system. I'm having trouble figuring out a way around this.

Originally I had hoped that I could disengage completely between gears, as in disengage from first, take ~200ms to brake the motors to proper speed before engaging second to minimize that mechanical shock. Right now I'm a little lost on how I can manage this. Is there an easy way to accomplish this? Maybe an easy way to operate the Forward Band? Any ideas are always appreciated. Thanks guys.

I'm not sure about NY (where the car would be coming from, as it is) but in Massachusetts once the car is electric, it is exempt from emissions, thus no OBD2 scanning. Just a safety inspection. Massachusetts does require a more detailed inspection, however, if you ever change the engine in the car from stock, but I'm not sure whether or not that applies to EV'*.
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Old 03-09-2011, 10:59 PM   #10
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Thats a thinker right there.

If you are serious about a high horsepower build, I would really just go with a manual. For 1/4 racing, just set it into 3rd. The electric motor has so much torque that it has no problem taking off in 3rd.

A getrag 282 or 284 5speed will drop right in. There'* also a 6 speed, but there'* no need for all of that.

You could also go with a 4T60 (no E). It uses a kickdown cable connected to the throttle to determine shift points. In fact, I don't think there are any electronics to it, except a speed sensor and a reverse light signal. Now that I think of it, there is power for the torque converter lockup. But you don't need that do you LOL.

But its your build and you dont have to listen to a thing I say.
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