Sunday, November 17, 2013

Is West Texas toying with Terry Hershner - stuck in the fog after finding a 100 amp charging station

This morning, Terry Hershner appears to still be stuck in West Texas.  When I went to bed last night he'd made it past El Paso, and was on the highway and looked like he'd make it to San Antonio or farther by morning.  This morning we see the report below, that they'd made it to the Iraan Energy House, where they have a Clipper Creek CS-100 that can provide 24 kilowatts burst charging power, and 16 kilowatts continuous, through one charging plug.  However, shortly after that he made another post about being stuck on the side of the road in thick fog.

Terry's traveling companion, Bun Bun, wrote this:
Trip update: visibility zilch (3-5 meters!)

Heavy fogs rolled through while recharging in Iraan... We've been traveling all night, but for about the last 50 miles we've been driving @30mph with deer throwing themselves at us!

West Texas appears to be playing with Terry?

It appears they've made it about halfway across, but they're close to the 2 day mark.  Once this fog burns off they'll be able to start rolling, and the charging stations are more plentiful as they head east.  Getting past West Texas is the big hurdle.  UPDATE: They just posted another link to a Glympse viewer, making it clear they're on the road again heading at 65ish miles/hr east from Ozona TX.  According to Google Maps it's 206 miles from there to San Antonio, so we should expect another stop for charging before that city.  Plugshare shows a KOA campground and that San Antonio is rich with charging stations. 

What Terry's overnight report reminds me of is the question in my mind - just how badly do "we" need "fast charging" anyway?

Some of the automakers appear to have been delaying electric car manufacturing plans to wait for fast charging standards to be fully tested and implemented.  Though, why didn't they just adopt CHAdeMO and get on with it is a mystery.

Anyway, the J1772 plug is spec'd to handle up to 19 kilowatts, which is 3x the charging rate that's common now (Leaf, Ford Focus Electric, etc).  For long trips like what Terry is doing, the charge rate effectively limits the speed of travel.  At 6 kilowatts the rule of thumb is you're gaining 20-25 miles of range per hour of charging.  So at 19 kilowatts it's more like 75 miles of range per hour of charging.  That's a pretty useful rate of charge.  With the 16 kilowatts continuous Terry says the CS-100 can handle, that's about 60 miles of range per hour of charging, still pretty useful.

Those figures are for cars - motorcycles require less energy than cars, so have a higher effective range gain per hour of charging.

If the car makers were to simply upgrade the on-board chargers to handle the full 19 kilowatts of the J1772 spec, electric cars would be that much more useful while not requiring expensive fast charger infrastructure.  The infrastructure would be more expensive than it is now, because 100+ amp circuits are more expensive to install than the 40 amp circuits required for a 6 kilowatt charging station.

The way things are positioned currently, the 6 kilowatt charging infrastructure is touted as "This is the Way Things Will Be" with nobody talking about upgrading level 2 charging above that power level.  That's leaving electric car owners stuck with 25ish miles of range gained per hour of charging.  And while that's much better than the 12ish miles of range per hour of 3 kilowatt charging, it's still not very fast.

For example, when I went to Craig Vetter's shop to visit with Terry and crew, I drove my electric car of course (because it's the only car I own).  The on-board charger is a Manzanita PFC-40 which can handle 8-9 kilowatts charging rate, but this is effectively limited by the rate supported by public charging infrastructure.  First, the voltage is typically 208 volts but sags to 205 volts during charging.  Second, the stations are configured for 32 amps max, and while the charger can handle 40 amps there's a risk of popping the circuit breaker if the charger is set above 32 amps.  That calculates out to 6 kilowatts or so.  The trip to Vetter's shop is 100 miles each way, and it took 4 hours of charging time each way, plus 1 1/2 hours driving time, making it 5 hours each way for a 100 mile trip.

What Terry has done to get around this limitation is to have multiple J1772 plugs and use multiple chargers.  If he stops at a charging station location with multiple charging stations, he can simultaneously charge from each station.  Two stations means 12 kilowatts, and three charging stations means 18 kilowatts.



Saturday, November 16, 2013

Terry Hershner takes on West Texas, this time geared up to win

It's 9pm PST, 1 1/2 days into Terry Hershner's trip in which he's attempting to set a record for cross country electric motorcycle travel.  The Facebook post embedded below was posted 5 hrs ago, from El Paso, his last status update a few minutes ago shows him now on the highway a few miles east of El Paso.  What Terry wrote on Facebook, "We're gonna try to be friends this time," is deserving of some explanation because Terry has some history with West Texas.

Over the last year he's made several cross country trips with his electric motorcycle.  It started with a long distance trip in early 2012 going from Florida to Tennessee for a conference.  Since then he's made trip after trip, continuously improving his bike and techniques.


Terry Hershner's bike as it was in December 2012
In December 2012, 11 months ago, Terry set off on his first cross-country trip.  The goal was to arrive in Los Angeles for the unveiling party of Zero Motorcycles' 2013 model line.  

He set off from Florida and I was following his Facebook updates with interest.  But.. then... there was this abrupt jump from West Texas to Los Angeles, and immediately before-hand Jeremiah Johnson had made a couple Facebook posts about driving his van through the night.

What I learned later is that West Texas was an insurmountable hurdle for Terry, at that time.  But now, Terry has the machine which can conquer West Texas.

Terry had counted on a public charging station owned by Oncor Electric in Big Springs Texas, that's shown on the ChargePoint maps.  But, the charging station turned out to be closed to the public.  While he was able to locate a big truck repair shop that let him use power outlets normally used by welding equipment, the long distances in the desert south-west were too much of a risk.

Terry Hershner and motorcycle,
in Craig Vetter's shop in October 2013
At that time he followed a pattern of riding 45 miles, then charging enough for the next 45 miles.  The south-west is so vast that charging opportunities are more than 45 miles apart.  Zero Motorcycles really wanted him and his bike in Los Angeles for the event, leading to Jeremiah driving to pick him up and together they went to Los Angeles for the event.

In other words, his first cross country attempt didn't achieve the goal of making it all the way across the country.  But, that didn't stop him.

Instead of returning to his home in Florida, Terry stayed in California, shuttling between the Los Angeles area and an apartment he rented in the Santa Cruz area.  Terry found collaborators in both areas and set about redesigning his bike for longer riding range and more energy efficient.  Rather than a 45ish mile range per charge, the bike now has nearly 200 miles range per charge.

As I wrote the other day, a key connection he made was to meet Craig Vetter.  Craig has been working on fairing designs for decades, and especially has focused on ideas he gathered while following Buckminster Fuller around - doing more with less.   Craig applied those ideas to Motorcycle Design with properly aerodynamic fairings so motorcycles would perform better, while using less energy.

For the last few years Craig has worked on the "Last Vetter Fairing" project.  The goal of this project is motorcycles that serve daily transportation needs while being extremely fuel efficient.  Over 100 miles/gallon fuel efficiency, while being able to carry 4 bags of groceries.



What's on Terry's bike is a version of that Fairing.  With it, his bike has well over 100 miles/gallon equivalent fuel efficiency, and can carry way more than 4 bags of groceries.  Or, in the case of this trip, tools and power adapters and cabling.


With that fairing, Terry has already ridden from California to Florida, then from Florida to the Canadian border north of Seattle, then from there to the Mexican border south of San Diego, then attempted to ride from California to Ohio, and in-between he's made several trips up and down California.  Just before this trip his bike hit the 50,000 miles mark, thanks to these trips.


Terry Hershner update - somewhere past Tuscon AZ

Overnight Terry Hershner and Bun Bun ran into a couple delays - an accident on I-10 that blocked the road for a few hours, and then strong headwinds that increased energy usage.  Even with that improved aerodynamic fairing, riding directly into a headwind still takes up a lot of energy.  They ended up prematurely draining the pack and having to charge on a 120 volt outlet.  They eventually made it to a GOE3 charging station from which they could draw 12 kilowatts - closer to their normal charging rate.

The last report I see on his Facebook page came 5 hours ago saying that a "drunk driver" had blocked the road for a few hours.  I assume that means a major traffic accident caused by a drunk driver ..etc.. and if we looked at news reports around Tuscon today it's probably full of gorey stories from the highway.


Because their last report was 5 hrs ago, one hopes that Bun Bun talked Terry into taking a nap ...








Friday, November 15, 2013

Terry Hershner sets off on new cross-country record setting attempt - San Diego to Florida in under 3 days

Terry Hershner's modified Zero S,
in Craig Vetter's shop
Terry Hershner has taken a 2012 Zero S - the same one which Jeremiah Johnson rode in the 2012 TTXGP World Final at Daytona Beach (see the video at the end of an article I wrote on him) - and modified it beyond belief to support nearly 200 miles on a charge, and a sub-1-hour charging time.  He's about to set off on another of his cross-country trips, looking to ride from San Diego to Florida in under three days.

Out of the box, the 2012 Zero S had about 60 miles range at highway speed and took 8 hours for a full recharge.

With his bike, Terry Hershner has criss-crossed the country this year demonstrating that the combination of 150 miles electric range and fast charging means the freedom to ride/drive "anywhere". 

The last couple months he's been working on further refinements with the intent to make another cross-country trip that will secure the record time for a cross country electric motorcycle trip.  Currently the record is held by our friends with Moto Electra, Brian Richardson, Thad Wolff, and crew.  Terry is looking to make the trip this time in about 2 1/2 days, but any trip under three days duration will snag the record.

How does it work?

The key is the charging system.  The bike is carrying, uh, IIRC it's 18 kilowatt-hours of battery pack, but it might be "only" 15 kilowatt-hours.  Stock, the Zero S ZF9 had 9 kilowatt-hours.  To charge that in under an hour means 18 kilowatts or more of charging capacity.  Terry has lashed a bunch of Elcon 2500 PFC chargers to the bike, enough to get 18 kilowatts -- if he can find sufficient charging stations or power outlets. 

Another part of the system is a bag full of power adapters.  The one shown here converts a J1772 plug into a NEMA 14-50 outlet, which Terry then converts further to connect with the chargers. 

His system lets him use multiple J1772 charging stations simultaneously.  Each typical J1772 charging station supports 6ish kilowatts, and by connecting to three stations simultaneously adds up to 18ish kilowatts.  If he can't find charging stations, laundromats typically have NEMA 14-50 outlets, plenty of electrical capacity, and he's become adept at talking laundromat owners into letting him charge his bike.


Another key is aerodynamics.  Terry has had the good fortune to meet Craig Vetter, a legendary motorcycle designer who has been developing motorcycle fairings for 50 years or so. 

Over the last year they've set up a full fairing for his Zero S - the idea being to make the most use of the energy carried on the bike.  They estimate that half of the range extension comes from Terry having installed a larger battery pack on the bike - 18 kilowatt-hours versus 9 - and that the other half comes from aerodynamics.

Vetter told me that one test of his fairing involved two Ninja 250's being ridden side-by-side, at the same speed, in the same air conditions.  One bike had his fairing while the other didn't.  The Ninja 250 with the fairing had something like twice the fuel efficiency of the one that didn't.

We believe that electric bikes need this much more than gas bikes do, because of limited energy storage.

For most of the year Terry had ridden with a fairing that ended in a blunt end.  That's the wooden bulkhead you see in the picture above.  What they did over the last two-ish months is to design, fabricate, and install the tail section shown above.  Adding the tail improves air flow and increases efficiency even more.  The technology used is amazingly simple, just an aluminum frame with a simple skin, but it makes huge energy efficiency improvements.

Craig Vetter overseeing installation of the tail

Testing the ride
Unlike his previous trips, this time Terry will have a passenger.  His friend Bun Bun will be riding behind him, helping him stay awake.  She's the one wearing the second helmet in the picture below.



Thursday, November 14, 2013

Brammo looking to go public in 2015, eventually build electric sports car

Brammo, whom we know mostly for ultra-fast electric motorcycle prototypes, and reasonably fast electric street bikes, is also looking to build an electric sports car for plus-sized people.  Ahem, like Brammo CEO Craig Bramscher.  If Tesla Motors' product plans seem eerily like the personal needs of CEO Elon Musk (first the sports car, then the family sedan, then the minivan), then maybe Brammo's product plans also fit the personal needs of its CEO.  Or maybe that's reading too much into it.  In any case, an article on the Sustainable Business Oregon website says that Bramscher's original purpose in launching Brammo was to manufacture a sports car that he himself could drive.

As a somewhat plus-sized person myself whose daily driver is an electric Karmann Ghia, the difficulty of getting in/out of a normal sports car is challenging.  I understand, really.

First - it says that Brammo is looking to go public in 2015 (or so) and raise $150 million.  The company has raised some investment capital already, and Polaris is a part owner of Brammo. 

The company has raised $17 million in investment capital in the last four years - a time period going back to 2009.  At that time the company had just competed in the 2009 TTXGP on the Isle of Man, had been a big sponsor of that race, etc.  The current fund raising target is $150 million from private investors, and another $150 million from public investors once they go public.

Bramscher's personal background is having launched a tech company, Dream Media, that did something related to creating "system infrastructure and connectivity solutions for communications companies such as Warner Bros."  He sold that company and made a mint, then used the proceeds as seed capital for launching Brammo.

His first thought after selling Dream Media was to buy a 'super-car' but, Bramscher said, "It turned out my 'petiteness' wouldn't fit into a Lambourgini or a Ferrari."

His thinking turned to building an electric car for what Bramscher described to Sustainable Business Oregon as "'pro athlete-sized' clients."

Read between those two lines and you get the description I wrote above - an electric sports car for plus-sized people.

According to the report, they've got an 85% complete prototype sitting in a storage facility in the Ashland OR area.  But then they took the pieces they'd been developing for the sports car, and instead built a motorcycle, and latched onto the idea of becoming an electric motorcycle company.

The electric sports car idea is still there, apparently, as part of the company's road-map.  And now that they're hooked up with Polaris, perhaps they have a manufacturing partner who can help bring it to market?

Wednesday, November 13, 2013

New electric motorcycle racing series for the US - under AHRMA auspices

Arthur Kowitz just posted an announcement in the Electric Racing group on Facebook (which I manage) titled - "Announcing a New eMotoRoadRacing Series in the USA!".  The announcement is basically that AHRMA will host an electric motorcycle racing series starting in 2014.  For the first year it's an exhibition series, that will have points and awards, and with "reasonable participation" it will become a regular class in the subsequent years.

The series will be held during AHRMA race weekends at these tracks
  • Roebling Road Raceway
  • NOLA Motorsports Park
  • Willow Springs Int’l Raceway
  • Sonoma(Sears Point)
  • Road America
  • Grattan Raceway
  • New Jersey Motorsports Park
  • Miller Motorsports Park
  • Barber Motorsports Park
  • Daytona Int’l Speedway
I queried him privately, and he says there's nothing yet public to link to for specifics.

He did say the series is open to "ePrototype, eProduction racer, or race-prepped eStreetbike".  I believe what he means is that the series is open to including the top end bikes (Lightning, Brammo Empulse RR, MotoCzysz, etc) and the middle-weight race bikes (Empulse TTX, Zero SR) as well as the street versions of those bikes (Empulse R, Zero S).  It may even be meant to include the DIY electric builders.

I think in practice that the series will primarily focus on what I called the middle-weight bikes .. Empulse TTX, Zero SR, Empulse R, Zero S, as well as DIY builders.

We'll have to see just where this is going.  In the meantime I have some questions, and no answers, but here's the primary one in my mind.

Are they cooperating w/ eRoadRacing?  What Azhar Hussain told me at the end of the 2012 season, is that  the TTXGP name would be freely licensed for use within club racing series.  There would be some conditions on using the name and rules, with the idea that TTXGP would become a production bike series with limited modifications allowed.  Maybe, or maybe not, this new series will be launched under that plan.


I'll wonder something out loud ... just because the TTXGP and eRoadRacing series' existed, does that mean we all need to treat that organization as the be-all-end-all of electric motorcycle racing?  Yes, the TTXGP and e-Power did valuable service in laying the ground work for electric motorcycle racing.  But, does that mean there can be no other electric motorcycle racing series?

The end goal is for electric motorcycle racing to take over.  But, how do we get there?  Do we work at the grass roots and build interest organically through club racing events?  Or do we build a world championship series from scratch?

Tuesday, November 5, 2013

Zero Motorcycles announces near-race-ready electric motorcycle, the 2014 Zero SR, while ditching dirt bikes

The 2014 Zero SR
Zero's first race-ready electric motorcycle
In the Laguna Seca corkscrew
Zero Motorcycles has ditched their dirt bike roots, and added a race ready version of the Zero S.  While this is exciting for electric motorcycle racing fans, it means electric dirt bike fans might be disappointed.  Or maybe not, depending on how good BRD's electric dirt bikes are.  But let's not get distracted by that, and instead focus on today's announcement by Zero Motorcycles of their 2014 product line.

The new 2014 Zero Motorcycles product line is primarily the core trio: Zero S, Zero DS, Zero FX.  The Zero SR is the race version, and there is also a Zero Police bike.  The press pictures area on Zero's website also includes pictures of a Zero MMX but that bike isn't listed on the front page as one of the 2014 models.  The Zero XU is missing as are the Zero X and Zero MX (their dirt bikes).  The Zero MMX pictures show a bike that's much like their old dirt bike design.
2014 Zero SR on Laguna Seca's front straight

Just in case you're confused if this
is a race bike or not

The Zero Motorcycles website does not describe the Zero SR as a race bike, but that's what it is.  To make that clearer, half the Zero SR the press pictures on Zero's website were taken at Laguna Seca.   They say: The “R” configuration of the Zero S is designed for riders who simply want to go faster and accelerate harder.  The difference between the Zero S, Zero DS and the Zero SR is that the SR has a 660 amp controller versus the 420 amp controller on the Zero S/DS.  In other words, the Zero SR has a SEVCON Gen4 Size 6 controller, while the S/DS has a Size 4 controller.

That controller difference is exactly the primary modification made during the 2013 eRoadRacing season by the guys riding 2013 Zero S's.

That means Zero is now offering, from the factory, a ready for racing motorcycle configuration.

Technically it's not completely race-ready in the same way Brammo's Empulse TTX is.  The Zero SR has mirrors and other doo-dads required for riding on the road, and doesn't have the tail switch and lights required by the rules.  Those are simple modifications however.  The big hurdle, upgrading to the Size 6 controller, is being taken care of by the factory.

The 2014 Zero S MSRP is $14,995, while the SR's MSRP is $16,995.  That makes the race-ready Zero SR to be a $2,000 price premium. 

For that price bump, torque goes from 68 ft-lb to 106 ft-lb, power from 54 hp to 67 hp, and top speed from 95 miles/hr to 102 miles/hr.  The 0-60 miles/hr time goes from 5.2 seconds to 3.3 seconds.  It's the same motor, so you're going to have to develop a cooling system.  At the 2013 eRoadRacing events, all the Zero based racers (except for Ted Rich) had installed ducts to direct air at the controller and motor.   Curiously they didn't upgrade the suspension components for the Zero SR.

Another new feature is an optional add-on battery pack that bumps total battery capacity from 11.4 kilowatt-hours to 14.2 kilowatt-hours.  That increases highway riding range from 70 miles to 88 miles.  This won't be of much help to racers because the 2013 bikes had plenty of range for the 22 mile distance of the TTXGP/eRoadRacing events. 

I have a niggling thought in my head, does the 14.2 kilowatt-hour pack give the bike enough range to complete the Isle of Man TT ZERO?  While it's not fast enough to be competitive for a shot at winning the TT ZERO, wouldn't it be wild for a factory built bike to go to that race and finish?  So far the TT ZERO has been all about prototype one-off bikes, and not about factory bikes.  Just like the 2013 eRoadRacing season was all about factory and manufacturer prototype bikes, bringing a factory bike to the TT ZERO would represent a big step forward.

Profile shot
Zero SR on the highway - it's not just for racing
The Z-FORCE 75-7 passively air-cooled, high efficiency,
radial flux permanent magnet, brushless motor.

Zero introduced this concept for the 2013 model year.
It is designed with the heat-producing components on the outside,
so that simple cooling fins can take care of cooling the motor.

The model number, 75-7, is the same for 2014
as it was for the 2013 Zero S.