Power2Drive 2022: Naext Kompensator N1 - a sustainable electric camper

The Seevetal-based e-conversion specialist Naext presented a VW T5 camping bus converted to electric drive at the Power2Drive in Munich, which implements a comprehensive sustainability concept. The vehicle, which has a 72 kWh underfloor battery installed - with future potential for up to 90 kWh - uses decommissioned CATL batteries from major automotive manufacturers, which are, however, fully functional. Additionally, the system relies on individually replaceable 18 kWh modules, and the converter offers a new warranty. These batteries had minor, non-functional faults, such as in the casing, and would otherwise have been shredded and required extensive recycling efforts, as Nick Zippel from Naext promotes at the booth. Through the conversion and refurbishment of the decommissioned postal van, the e-van, executed here as an e-camper, saves 80 percent of the energy compared to a newly produced e-van, i.e., 20,000 kWh of energy, seven tons of CO2, and 60 tons of resources per vehicle.

Like "embodied energy" in buildings

It’s similar to the concept of "embodied energy" in buildings, aiming for the most consistent reuse of already existing resources, Zippel explains. The conversion kit was developed with know-how from the aviation industry, using 3D scan and 3D printing technology, and in so-called "additive engineering," and is installed in old T5 and T6 models from Volkswagen within a few days. By the way, the battery management system and electronic control are also in-house developments, as Nick Zippel proudly reports. The price is expected to be around 35,000 euros. However, Zippel also recommends a refurbishment of the base vehicle. The exhibited e-camper with a pop-up roof was fitted with a modular setup by a specialist manufacturer, also entirely with sustainable materials like wood or steering wheels with reprocessed leather.

Preserve as much as possible: Manual transmission for towing capability

The range of the E-Van, which can reach speeds of up to 160 km/h, is 350 kilometers under summer conditions and 250 kilometers in winter. Charging is done via AC, with up to 20 kW capacity through a unit practically built into the grille. A 110 kW electric motor with a generous 255 Nm torque, installed in the engine compartment and connected to the existing manual transmission, provides drive to the front axle, thereby maintaining the towing capacity – a point that was very important to the team from the north. Also important is the aspect of "second life": If the battery modules no longer have enough juice for mobile use, which is monitored using the battery's "life log," the manufacturer guarantees buyback for a refund, of course, not without ulterior motives.

In the second life, the batteries serve as buffer storage and chargers

After all, the second product in the portfolio is called Hexagon and is nothing other than a stationary 400-volt battery buffer storage and combined booster charger, which is "scalable" up to 500 kWh and delivers up to 22 kW in AC and 64 kW in DC. The power demand for stationary storage is 15 times lower than in mobile applications, so the "fitness" of the used and already repurposed batteries is more than sufficient.