Lunaz Design

Technology

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Technology

Our goal is to make the worlds finest electric converted classic cars by using state of the art technology and manufacturing techniques to maximise range, performance and usability all while catering to your individual needs.

A modular Powertrain solution

At Lunaz Design we do not intend to specialise in any particular vehicle marque so it is really important to us that we are able to adapt our Powertrain solution to fit in as many different vehicles as possible. We have chosen an electric motor supplier that offers a range of motors which all come in very similar shaped casings and which have similar electrical drive requirements but cover the range from 135 bhp to 590 bhp. The same is true of our inverter supplier and for the larger power outputs we just fit two. All of our power trains are controlled by our in house developed Chassis Control Unit (CCU) which is programmed directly using industry standard Matlab Simulink models by our own development engineers. The CCU forms the hub of our Powertrain solution allowing us to programme exactly the functionality we want, allowing new features for a classic car like traction control, cruise control and driven wheel slip detection under regenerative braking. It also enables us to send outputs to the vehicle dashboard that allows use of the classic original instruments to display speed, revs, temperatures and to repurpose, for example, the fuel gauge to display battery state of charge.

Battery size, vehicle range and performance

Key to the performance of any electric car is the size of the battery. The larger the battery the longer the range of the car, but also the less stress is placed on each individual battery cell, so the battery life will be longer, you can extract more performance for short periods of time and you can charge it more quickly. In order to fit the largest batteries we can in our cars we make our own battery packs in house. Using a modular design that allows us to position the battery cells just where we want them we can use all of the available space on each car. It is common for our cars to have two battery packs, one in the engine bay and one under the floor of the boot (trunk) where the petrol tank used to be.

What about battery life?

At Lunaz we use only brand new battery cells from reputable manufacturers that sell similar parts to mainstream car makers. We will never use a cell with a life expectation of less than 1,000 full charge and discharge cycles. As our vehicle range in normal use is typically more than 250 miles this minimum battery life equates to 250,000 miles of regular use. We can of course supply replacement batteries when the time eventually comes and we will be pleased to support our cars forever. We do not foresee any reason why any of our cars would ever actually become obsolete, because even if an original part becomes unavailable we can always design and make a replacement.

Production ready

Only components that are in full production in significant quantities are chosen. There are many companies starting up in the electric vehicle technology space making electric motors, power electronics, batteries and the like. These brand new products often promise improved performance, better efficiency or lighter weight but they are not able to promise reliability, security of supply or spares back up. At Lunaz Design we use our industry knowledge and do our homework to ensure that we pick components which meet our strict requirements. We want the latest technology, but only if it is genuinely mature enough to be reliable and supportable in production.

Only new replacement parts

On our cars every part is either restored original or new. Unlike many of our competitors we do not use secondhand parts to complete the conversion. We understand why it is tempting to use battery modules or electric motors from a used electric car like a Tesla, but most of these secondhand parts will have come from crashed cars and the history and mileage of the parts is unknown.

If it has to be made just for us then WE make it

If we are unable to source a particular component or assembly from a supplier that meets all of our criteria then we will make it ourselves. We have the skills in-house to design and make anything at all for a car, so we can never get stuck in the position where we are unable to do something. We use the latest Computer Aided Design software from SolidWorks to produce 3D models of all our bespoke components and we typically subcontract the machining of our metal parts, but we do have a fully equipped R&D room with metalworking machines for making one off parts and for final adjustments. We have skilled fabricators on site who work with metal forming equipment MMA, MIG and TIG welders and we use the latest 3D printing machines to produce the low volume plastic parts that are used inside the battery packs and behind bespoke pieces of interior trim.

Is the conversion reversible?

If a client really wanted to reverse the conversion then yes of course it could be done, but why would anyone want to? We think this is so unlikely that we do not treat reversibility as a design constraint. This allows us to modify areas of the car such as the boot (trunk) floor in order to fit more batteries and build a better electric car.