Long before any of the students who participated in the development and build up of the Ohio Technical College's new Electro-Van were born, General Motors had already produced a vehicle by the same name. The 1966 Chevrolet ElectroVan used a liquid hydrogen and liquid oxygen fuel cell to produce electricity that powered an AC induction motor.
Like his students, Tim Cole, Instructor in the Alternative Fuels Division of OTC, was not aware of the original ElectroVan, but that didn't stop him from conceiving the idea and leading a team of 13 students as they converted a 1997 Ford Econoline E350 van from diesel to pure electric power.
Cole said, "Our goal is to help our students gain technical skills while they learn how to troubleshoot and be innovative with their solutions." Students enrolled in the Ohio trade school often become service technicians. What they learned building their Electro-Van should prepare them for working on today's generation of hybrid and electric vehicles.
The Ford Econoline was donated to the school and was in a poor state of repair. The OTC includes other automotive-centric programs, including auto body repair, auto restoration, and custom auto painting. Each of these groups contributed to the six-week project. "Coolest thing about the whole deal, is the way the whole college came together to make this happen," Cole said.
Working with only donated parts, including an electric motor from a fork lift, the team used 21 12-volt deep cycle marine batteries arranged in seven parallel wired groups of three batteries. Currently, the ex-fork lift motor runs on 36 volts and produces an estimated 95 horsepower. The voltage is the speed-limiting factor for the van, which currently tops out at 35 mph. An on-board charger plugs into a household current for overnight charging.
The motor is capable of handling more voltage, and as the Electro-Van is updated by future classes, voltages and speeds are expected to increase. Currently, the van has a two-hour run time, aided by regenerative braking. Solar panels that will be mounted to the top of the van have been ordered in an effort to extend the van's range.
Tom King, director of Enrollment Management, Ohio Technical College said, "As the world continues to get greener, it's vital our students are trained and knowledgeable about the products, technologies and processes involved in creating, converting and maintaining alternative fuel vehicles."
The automotive program of the Ohio Technical College is NATEF and ASE certified. Additionally, since no program like this is possible without sponsors, the college wanted to recognize Pro-Class; Ralph H. Phillips Companies; T & K Welding Co. Inc.; A & B Grinding; Bills Transmissions; Ohio Materials Handling Inc.; Interstate Batteries; Goodyear; GC Supply Inc.; Kirk Battery; and Modern Tire Mart Inc.