Charging While Driving w/ Gas Generator in Bed (Range Extender for F-150 Lightning) - Testing

[maxwell.pappas]

Martin is about ready to take the first real road trip with this system towing, so look for that in a few weeks.

Super interested in direct DC charging while driving/stationary to use solar panels on a truck cap to basically offset all the accessory use while traveling and camping/over landing.

Would I guess also work to create a defacto extra battery pack in the bed.

Does the system you are creating only work through the AC system, or could it use DC to improve efficiency of converting DC sources of power?

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[ZSC100]

Super interested in direct DC charging while driving/stationary to use solar panels on a truck cap to basically offset all the accessory use while traveling and camping/over landing.

Would I guess also work to create a defacto extra battery pack in the bed.

Does the system you are creating only work through the AC system, or could it use DC to improve efficiency of converting DC sources of power?

What we are doing is just supplying AC to the on board charger just as an EVSE does. So, with generators, this makes sense b/c all generators generate AC power. Going DC to the vehicle would be fairly easy, but would need a very good DCDC converter with programming or a control module to interact with the vehicle for safety interlocks and coordination. The real problem with your ambitions is that you just can't get much power from solar within the footprint of the truck. I'd guess not more than 1kW. And with a 100KWhr battery that's just not much.,, maybe 3-4kWhr/day. If you had deployable panels, it's possible I guess to get more for like camping in remote areas. I'd say if you really want to go this route just get the cheapest MPPT solar panel battery charger with 400V output there is. There's no cheap/easy way to make DC charging work unfortunately. But this is your cheapest route, something like this
https://www.tanfonsolar.com/solar-charge-controller/high-voltage-mpptsolar-charge-controller.html

You can get on the DC accessory bus very easily, just pull the frunk tub and it's all over the place.

 

[maxwell.pappas]

What we are doing is just supplying AC to the on board charger just as an EVSE does. So, with generators, this makes sense b/c all generators generate AC power. Going DC to the vehicle would be fairly easy, but would need a very good DCDC converter with programming or a control module to interact with the vehicle for safety interlocks and coordination. The real problem with your ambitions is that you just can't get much power from solar within the footprint of the truck. I'd guess not more than 1kW. And with a 100KWhr battery that's just not much.,, maybe 3-4kWhr/day. If you had deployable panels, it's possible I guess to get more for like camping in remote areas. I'd say if you really want to go this route just get the cheapest MPPT solar panel battery charger with 400V output there is. There's no cheap/easy way to make DC charging work unfortunately. But this is your cheapest route, something like this
https://www.tanfonsolar.com/solar-charge-controller/high-voltage-mpptsolar-charge-controller.html

You can get on the DC accessory bus very easily, just pull the frunk tub and it's all over the place.

Thanks for the reply

Under no impression that solar power would be a way to meaningfully power the truck for driving- it is just that your project is very interesting in that once there is a way to provide power to the vehicle when it is underway and without using a hard-wired "station", the possibilities really seem to expand significantly.

I saw you had some videos up, and I certainly appreciate that, since it makes it easier to assess if it is something I'm willing to do to my truck. It isn't that I would ever be interested in the gas generator specifically, it is more that once there is the ability to charge with ONE thing, it means that you can charge with LOTS of things, and that is I think the unique thing about electricity that makes it more versatile long-term than ICE. I can't refine gas in my backyard, but there are a WHOLE bunch of different ways to make electricity.

Thanks for creating something that people are looking for!

 

[V8Nissan]

I like it. Many times in cold weather I'm on the ragged edge of range facing unreliable and sparse fast charging ability. Would be nice peace of mind to throw my generator in the bed for the trip home at Christmas! Would add an extra 30ish miles which makes the difference for me. Anyone worried about "storing and transporting fuel" probably worries about a lot of other things too lol. I used to haul cans of sumped jet A around daily for use in my 7.3 powerstroke. I also used to run a harbor freight generator in the bed of my 1981 rabbit pickup diesel utilizing a space heater on my hour commute and while parked at work for a block heater. Just like an auxiliary power unit on the 767s I used to work on. It was a free vehicle that enabled me to garage my 370Z roadster in the winter.

 

[ZSC100]

I like it. Many times in cold weather I'm on the ragged edge of range facing unreliable and sparse fast charging ability. Would be nice peace of mind to throw my generator in the bed for the trip home at Christmas! Would add an extra 30ish miles which makes the difference for me. Anyone worried about "storing and transporting fuel" probably worries about a lot of other things too lol. I used to haul cans of sumped jet A around daily for use in my 7.3 powerstroke. I also used to run a harbor freight generator in the bed of my 1981 rabbit pickup diesel utilizing a space heater on my hour commute and while parked at work for a block heater. Just like an auxiliary power unit on the 767s I used to work on. It was a free vehicle that enabled me to garage my 370Z roadster in the winter.

Awesome, ok just for you: I will make an Easter egg calling the generator an APU.

 

[doggod]

this is a bad idea. making the vehicle drive while charging will allow the vehicle to move while at a DCFC charge station. which will lead to someone forgetting to unplug and causing damage to vehicle and charge station and lead to fires and electrocution.

 

[ElectrifyingMe25]

this is a bad idea. making the vehicle drive while charging will allow the vehicle to move while at a DCFC charge station. which will lead to someone forgetting to unplug and causing damage to vehicle and charge station and lead to fires and electrocution.

Of course there is an extra burden of responsibility on a CWD pioneer. But Columbus didn't let that stop him, and look at what we got out of that.

 

[ctuan13]

I personally can't wait to see the finished product. In many ways, this is exactly what I've been looking for, to use on my cross country road trips while towing my teardrop trailer. Only issue might be exceeding my payload capacity, considering I already bring a lot in the way of food and supplies with me.

I've already purchased a second gas truck for this purpose, but if this were to be available by next spring, I'm far from opposed to giving it a try on my trip out west.

There were countless occasions where despite technically being able to make it somewhere, having so little margin in my range, meant I was uncomfortable or completely unable to explore, sightsee or otherwise engage in more leisurely activities that even slightly deviated from the direct path to the next DC charger.

I've been following this closely and will continue to look forward to more info in excited anticipation!

 

[doggod]

I personally can't wait to see the finished product. In many ways, this is exactly what I've been looking for, to use on my cross country road trips while towing my teardrop trailer. Only issue might be exceeding my payload capacity, considering I already bring a lot in the way of food and supplies with me.

I've already purchased a second gas truck for this purpose, but if this were to be available by next spring, I'm far from opposed to giving it a try on my trip out west.

There were countless occasions where despite technically being able to make it somewhere, having so little margin in my range, meant I was uncomfortable or completely unable to explore, sightsee or otherwise engage in more leisurely activities that even slightly deviated from the direct path to the next DC charger.

I've been following this closely and will continue to look forward to more info in excited anticipation!

the tank on generators is only 1-2 gallons so not likely to much range unless you want to stop at gas station every 15 miles or add another gas tank which would be illegal to drive on road in most states. I owned a BMW with range extender and could only get 30-50 miles on gas engine. and it had 4.5 miles per Kwh.

 

[ZSC100]

I personally can't wait to see the finished product. In many ways, this is exactly what I've been looking for, to use on my cross country road trips while towing my teardrop trailer. Only issue might be exceeding my payload capacity, considering I already bring a lot in the way of food and supplies with me.

I've already purchased a second gas truck for this purpose, but if this were to be available by next spring, I'm far from opposed to giving it a try on my trip out west.

There were countless occasions where despite technically being able to make it somewhere, having so little margin in my range, meant I was uncomfortable or completely unable to explore, sightsee or otherwise engage in more leisurely activities that even slightly deviated from the direct path to the next DC charger.

I've been following this closely and will continue to look forward to more info in excited anticipation!

We would never sell a product that would allow you to pull off with a charger connected. This is a professional implementation of a feature Ford has already made provisions for behind the scenes. It will be fully tested and 100% safe before we ever offer it to anyone for DIY use.

 

[ElectrifyingMe25]

the tank on generators is only 1-2 gallons so not likely to much range unless you want to stop at gas station every 15 miles or add another gas tank which would be illegal to drive on road in most states. I owned a BMW with range extender and could only get 30-50 miles on gas engine. and it had 4.5 miles per Kwh.

30 to 50 extra miles could make all the difference sometimes. I love thr idea of having a range extender. I'd probably use a large LFP battery pack in the bed or trailer I'm pulling and a pure-sine-inverter to make the 240V connection.

 

[ZSC100]

30 to 50 extra miles could make all the difference sometimes. I love thr idea of having a range extender. I'd probably use a large LFP battery pack in the bed or trailer I'm pulling and a pure-sine-inverter to make the 240V connection.

This is the beauty of a DIY kit. With a bed port that allows CWD you can do whatever you want. I'm amazed at all the people who want to use it for batteries. I can't wait to see what people do with it.

 

[ZSC100]

 

[ElectrifyingMe25]

Great video. I support you 100%
I'm looking forward to buying your kit.

Go man, go!

 

[NW Ontario Ford Lightning]

This is the beauty of a DIY kit. With a bed port that allows CWD you can do whatever you want. I'm amazed at all the people who want to use it for batteries. I can't wait to see what people do with it.

When you have it ready I want to be an early adopter and test it out.
I have 45kWh of LFP packs ready to go, they fit perfectly three x 15kWh side by side across the bed, a 12kW inverter fits right on top, and (importantly) the tonneau cover can remain in place and closed over the whole works. The battery packs together weigh about 600 lbs.
This would allow the SR 98kWh battery truck to be extended out to a 143kWh battery when needed, but removed when not needed. Very cool.
The genny in the bed is less interesting to me, but it is good to know that is another option if/when needed.

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