Thanks Idontwanttopedal and lostrack!
Oh, what a night...
Yep, gear selection it is + option of coasting or regen + torque protection + redundancy + compact simplicity
is making custom extended "lower's" for this bike, it got me thinking in a whole new direction! I like the idea of a longer wheel base for added stability at speed, the prospect of being able to put more power to the ground before lifting the front tire, and the added strength of steel over the stock aluminum. I'm still just hoping he can accommodate my design ideas as he is not familiar with all I have in mind yet, but that should be clarified soon as I will point him here to check it out.
The bullet points of my design are these:
1. Every part of the drive train will be mounted on the new custom lower of the rear suspension, or on plates that mount to the new lower, going directly to the back wheel hoping to get good efficiency and durability.
2. This leaves more room for batteries and such in the frame of the bike, and possibly will allow me more freedom in design when it comes to a final look for hiding it all.
3. This design gives me, what I think, will be all I wanted in my ebike system with the fewest parts and the least complexity as it is basically a drive train and gearbox and regen (option) all in one...with redundancy to boot to get back home if something that is "doubled" does give up while I'm "far-far away".
Breakout explanation of the components and their functionality:
1. Small Green
"pinion" gear: motor pinion, fixed, self explanatory.
2. Large Green
"spur" gear: This will be captured within a torque limiter, giving me full drive train protection. (Need to figure out the torque rating needed here!)
3. Small Blue
"pinion" gear: This will be fixed to this jack shaft and spin full time.
4. Large Blue
"spur" gear: This will be mounted to a freewheel and be the low speed high torque work horse. (ACS crossfire or better?)
5. Small Red
"pinion" gear: This will be mounted in a bearing and be freewheeling, but can be engaged by a dog for "2nd gear" and/or a "regen option".
6. Large Red
"spur" gear: Fixed mounted behind and with the disk brake via a "Top Hat" ( http://kingssalesandservice.com/
, I think I will be getting most of my sprockets from them, especially the big ones!)
7. Small Gray
gear on the right side of the wheel axle: This is just a normal freewheel that will connect to my bikes original crank for 3-speeds of peddling, if needed.
Here's how I "think" it will work:
1. From take off, in "first gear", power will be transmitted from the motor to the torque limiter and on to the Blue
"high torque/low speed" gear set, to the wheel through its' freewheel.
2. Once the 1st gear speed limit is reached (~15-20mph?), I select second gear by shifting to engage the Red
gear via a dog (thanks Thud!), until top speed is reatched...
While in 2nd gear I have some choices:
1. Stay at speed by maintaining a throttle position/cruise.
2. Coast by letting off the throttle and switching back to 1st gear/freewheel, thus disengaging the high speed/fixed side.
3. Slow down using regen (if equipped) by staying in the 2nd/fixed gear and activating said regen.
And this is all within this simple drive train!
To complete the analogy there are still the "other options" of:
1. Peddling at 3 different speeds using the front dérailleur.
2. Using the disk breaks to slow down faster and to come to a complete stop.
OMG, it's getting late again! And boy did I get carried away with the numbering?!
Of course I don't have this ALL figured out yet and I've got a lot of questions I hope the experienced genius's here can help me with...but we'll leave that for another time.