My ultra-sufficient semi-recumbent tricycle project

General Discussion about electric bicycles.

Re: My ultra-efficient semi-recumbent tricycle project

Postby ddk » Tue Apr 10, 2012 2:59 pm

ddk wrote:who said stokemonkeys are hard to do?

likely anyone who's attempted to make a homemade chain drive. :lol:

no pics... it's raining again.
This might be caused by living in a rain forest

On a three-mile test (*Reality Speaking*- picking up his shipment of LiPo batteries recently purchased from HK)
my final drive chain from the jackshaft to the gear cluster came off!
While all sorts of scenarios tumbled around my head on the trip back home, what actually happened is mr-know-it-all either forgot, or inadequately tightened the setscrews on the collar stop for the left bearing.
The bearing worked it's way to the right, freeing itself from the bearing hanger ( "FREEDOM AT LAST!!!")
The end of that story.

Having two motors controlled by two different throttle systems and two sets of batteries allows for a SUPER EFFECTIVE safety margin in all it's redundancy redundancy
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-defficient semi-recumbent tricycle project

Postby ddk » Tue Apr 10, 2012 9:54 pm

OK
more anti-progress
the stoke-the-monkey along with the front motor climbs trees (no, not really but My Trike(TM) effortlessly climbed the 15% hill)
uhm, one *cough cough* minor setback.
-pedaling backwards derails the jackshaft drive chain
note-pushing the trike backwards doesn't have this effect, which is why I missed it.

what happens is the derailleur arm* bunches up because the backwards-pedaled chain is trying to reverse-drive the MY1018 motor.
Hey, did I ever say I've done the gearing this way before?
DID I?
(quiet down, rabble-rousers, rabble rozers, ribble roosers... whatever)
AND STOP LAUGHING SO LOUD!

Mr-know-it-all now knows something he didn't before this moment in time (but immediately thinks of a simple fix)(because that's how I roll)

solution: add a reverse freewheel on the jackshaft gear that drives the derailleur gear cage
(see picture)
complete drive train 4 10 2012.jpg
duh yup
complete drive train 4 10 2012.jpg (15.72 KiB) Viewed 439 times


---cha-ching about ~$20 if I read Stanton-inc's web site properly... if I. misread it then ~$35... -or ~$20 for the 15-tooth freewheel + ~$15 for the 5/8" axle adapter. (+ whatever shipping will be)
Stay tuned because:
We'll find out tomorrow

*If I didn't feel the need to always have the option of a pedal-only trike, I would just drop the derailleur arm altogether.
Otherwise with both motors I have no real need to ever shift gears.
BTW the stoke-the-monkey has a top speed of 5-6MPH on the flat and LOL 5-6MPH on a 15% grade.
***successful gearing guesstamation-proven by pudding*** the 15-tooth freewheel will change this a little bit i.e slightly faster on the flat and slightly less guder on the 15%
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-defficient semi-recumbent tricycle project

Postby ddk » Wed Apr 11, 2012 4:52 am

if Hobby Kreeps doesn't get their back-ordered +1010B chargers in stock soon I'm gonna have to re-evaluate my charging requirements.
Charging multiple bricks of 5S cells with only one MAX80 charger is detrimental to my mental.

on a different note: in the past two days 2 sets of 2x6volt batteries on my solar system have failed. After six years the Energizer Bunny took a walk!
(the batteries were marketed as Energizer batteries but were manufactured by (if I remember right (unlikely)) Interstate Battery)
I guess it's time I put all those Rassy-supplied SLA batteries to use, as I've only been de-sulfurcating them or otherwise rejuvenating them. But so far only two have recovered completely.
Although my solar batteries have all failed I still have two in-fairly-good-shape Costco 6V batteries on the line/gen/motor re-charge system so I don't lack for a 12V source... which is gud because I'm looking at a financial meltdown in my checkbook
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-defficient semi-recumbent tricycle project

Postby ddk » Thu Apr 12, 2012 3:15 am

today's off-topic discussion point:
living with LiPo...

Having decided (due to cost) to power My Trike with R/C LiPo , as so many before me, have had these same insights.
1) LiPo batteries don't seem to easily get unbalanced unless you discharge them below 3.5V or so.
Therefor it's best not to discharge them below 3.5V or so (yup)
2) Bulk charging makes the most sense if your battery array is over 2 packs in parallel or 3(packs) in series because the wait time is awful using (one) balance charger. (one balance charger per paralleled battery seems to make sense, however)
3) Not knowing if anyone noticed this, but if you happen to leave your battery's balance leads and discharge leads plugged into your un-powered MAX80 balance charger overnight what happens is ... nothing.
The battery doesn't discharge at all... so I'm gonna conclude this is a safe thing to do, although I only own the MAX80 and none of the other HK chargers.
4) Of the 8 Turnigy 5s 5000ma @20C R/C LiPo batteries I now own I have two slightly over-rated packs, 3 slightly under-rated packs and 3 packs the are close enough to be called "just right". I have no fear of mixing the packs in any misch-mosh manner, although I've marked the slightly over-rated packs for reference.
5) there is, atm, no fifth point to make...

I haven't made up my mind about my charging needs. HK continues to lack stock of the few balance chargers they supposedly sell that interest me the most. (never in stock)
I suppose it's time to visit other on-line hobby stores.

If I were to build solar panels for My Trike(TM) at this point in time I would just go ahead and wire the cells for 42V and forget about using a MPPT, instead opting for a simple voltage cut-off circuit.
Note- an MPPT only really "kicks" in when a battery is within 20% of being recharged any ways- at least that's how three different manufacture's MPPTs I'm familiar with work. Before that point the MPPT bypasses itself connecting the solar panel array's total output directly to the battery---- "the more you know..."
yawn
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-defficient semi-recumbent tricycle project

Postby ddk » Thu Apr 12, 2012 7:33 pm

see pic

the 6V on the right's been spewing it's acid all over the place :shock:
dead bunny.jpg
born to die
dead bunny.jpg (55.78 KiB) Viewed 416 times


the battery's plates were exposed to the air and warped to lala land

rest in peace...
I've only had to check/fill the water level in this pair once a year (although I checked them twice a year). Both batteries were good to go in December
but not no mo'
The battery on the left is likely still good but I'm gonna replace them as a pair
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-defficient semi-recumbent tricycle project

Postby ddk » Fri Apr 13, 2012 7:40 pm

dropped in @LBS to get gear grease (I LIKE small amounts of grease for larger amounts of dollars)
Started talking about the gear ring from Rassy and what might be a suitable bolt. We go back to his used bike parts (shop) and digging around for a 56-tooth chain ring when he spies a BMX to 48-tooth chainring adapter plate

"So, how much?" (me)
"Oh, I dunno. That's a rare and exotic part..." He reply's
"Rare and exotic like a Huffy single-speed bike?" (me)
"And it's called a "Power Plate". THAT'S gonna cost you more..." (him)

$10 for the adapter plate and $4.5 for the bolts later I need to add 4 links to my chain...
...and I forgot to buy the gear grease :roll:
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-defficient semi-recumbent tricycle project

Postby ddk » Fri Apr 13, 2012 8:30 pm

56 tooth chainring.jpg
bigger than life
56 tooth chainring.jpg (60.09 KiB) Viewed 399 times


re-installed the 142mm crank with the 56-tooth chainring:
Top Speed ~ 30MPH (if I wanna crank the pedals @90RPM -which I don't)
I'll never be able to start in 6th gear again -although 2nd gear will get me up the 8% grade, which means the two motors will get me up the steeper hills without a problem

verdict: SUCCESS!
-56-tooth chainring is likely the best compromise for My Trike(TM)

Thanks Again, Rassy! :D
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-defficient semi-recumbent tricycle project

Postby ddk » Sat Apr 14, 2012 9:26 pm

today was a GREAT day to ride a tricycle
which meant I decided to screw around with the seat.
I'd forgotten why I'd assembled the seat bass-ackwards so I re-assembled it in the Way Of Belize
- went through the same hilarious fumbles as described on Page 1 of This Thread ,..but with the help of my neighbor we managed to 'get er done'
My neighbor took off to enjoy the day
I loaded up batteries, sat on the trike
*NOW I remember*
too late, the neighbor left.
Installed the Belize Way, the seat is Too Far Forward by almost 5" making me crab my legs on the pedals with my knees almost touching the handlebars. ***And My Center Of Gravity Has Shifted***
But I thought-a quick trip to the lumber yard... get some ply... build a new seat-
batteries on... why change trikes?
so off I went
Bought useless stuff and rode back when a truck decided to pull out smack in the middle of the of the drive leading to my abode.
I carefully maneuvered around him but the crown of the drive to the right of the truck was so steep the trike started to tip over.
I was trapped by my legs and the handlebars so slo-o-w- lee over I went.

ouch.
Which gave me another emphany.
(pain does that to me sometimes)
Instead of building a new seat; modify the existing seat with extension brackets, solving the seat's location AND installation problems at the same time!
seat mod 2.jpg
need one shorter bolt LOL
seat mod 2.jpg (24.18 KiB) Viewed 384 times

seat mod 1.jpg
another angle
seat mod 1.jpg (29.81 KiB) Viewed 384 times


done
works great
I has sum lumburz I don't needs.
lumber After the Fall.jpg
sticks and stones...
lumber After the Fall.jpg (56.31 KiB) Viewed 384 times
seat mod 3.jpg
YET another view of the seat bracket
seat mod 3.jpg (16.77 KiB) Viewed 306 times
Last edited by ddk on Thu Apr 19, 2012 11:04 pm, edited 1 time in total.
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-defficient semi-recumbent tricycle project

Postby ddk » Sun Apr 15, 2012 6:04 pm

'nother day
and it's spitting rain

Time to build the battery box(s)
Decided against the "in-the-frame" approach because I don't want or need to bend that far over (see:above post)
Since I was still wishy-washing about the dashboard, I thought I'd start there.

Although it makes perfect sense to me to hang batteries over the fork by offsetting their weight with all the stuff I'd like to have in front of my face... it can't happen. (has to do with the 'undisclosed' solar panel holder-uppers (teknical term- means "I dunno yet"))
That limits the number of batteries I should consider hanging on the handlebars (weight, and all that goes with it)
...so I'm thinking 4 bats for 2.6kg thereabouts
There's also a charger (maybe) front motor controller, some battery monitors, two voltmeters and the structure of the dashboard itself getting the total weight up to ~7kg.
-I think this should work ok. (until I have some possible disastrous result :lol:)
Having only 10AH of battery up front determined my design of the rear bat box(s) (I'm gonna build 2 but expect to fill half of 1 for an additional 20AH -lol)
So...
using my precision methods of measuring stuff, I laid out the dashboard


dashboard.jpg
precision layouts LOL
dashboard.jpg (42.11 KiB) Viewed 368 times

I cut out the pieces from 6mm oak plywood.
and then started my battery box(s) design that becomes 'semi-retro' rear fenders to go along with the theme of 'semi-recumbent' trike.
No mo' pics. it started raining
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-efficient semi-recumbent tricycle project

Postby ddk » Wed Apr 18, 2012 8:01 pm

raining, bored, listless, bored off topic ramblings... read no further

Having installed the 56-tooth chainring, causing my pedal cadence to decline sharply, along with the shorter, or shortest cranks an adult-legged person should consider using (142mm), solved my knee and leg muscle complaints.
however, it's still raining

have a nice day
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-defficient semi-recumbent tricycle project

Postby ddk » Fri Apr 20, 2012 10:47 pm

although the day started and ended in a fog (like my brainnnnnnsnsnssss)
mid-day saw an unusual object in the sky; the sky responded by breaking out in blue wonder.
It was sunny with an uncluttered sky to boot!

Back to work on My Trike(TM) ...after some interruptions involving riding trikes for the heck of it.
One of those random rides took me to the sign shop where my 4x8 sheet of 10mm Coroplast awaits me.
I thought to use the some trim pieces off My Sheet for the rear My Bat Boxes.
Instead the proprietor gave away some scrap pieces and sold me (cheap) some chunks of leftover 4mm black Coroplast he'd used for a sign several years ago. (woohoo)
One of the scrap pieces, about 12x18 inches, features a portrait of one of those kings of England... a German fellow I gather.
The king might make an interesting dashboard...LOL

Anyway I started making what yesterday I thought might be a nice looking bat box.
Upon setting it in it's intended position I immediately HATED the thing. But it iS big enough to hold tools, controllers, a small army + reinforcements in the opposing box (one box per side of the seat) ...or 150 5S 5000ma sticks
WTF was I thinking yesterday? Must not of remembered my drugs...

too biggy.jpg
could hold 75 5S 5000ma sticks
...like I wanna carry 7-14KW of batteries on a tricycle
too biggy.jpg (54.2 KiB) Viewed 261 times
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Sat Apr 21, 2012 10:15 pm

woke up to fog
went back to sleep
woke up to less fog
time to ride!
lost my ambition building battery boxes so I re-mounted my BigBlackCase
and headed out. Being almost smart I bundled up an extra coat in case the day got foggier. Or foggiest.
Due to the topography here I knew I could count on...nothing.
One moment bright...hot...sun.
Next moment damp...cold...fog. etc etc etc lost count.
Meanwhile customer comments included a teenager "woah...sweet bike!"
To SumOldFart askn' "What's in the the box bub... yer laundry?"
bat box temp0.jpg
it's a mystery
bat box temp0.jpg (24.88 KiB) Viewed 241 times


*Opens the case*

bat box temp1.jpg
"my lunch"
bat box temp1.jpg (38.95 KiB) Viewed 241 times



WTF IS THIS HERESY?

bat box sw.jpg
"it's a switch"
bat box sw.jpg (29.43 KiB) Viewed 241 times


One of Radio Shack's finest in automotive switche, $3.75... too cheap to wanna buy a nicer automotive switch and $15 shipping and handling seems, uhm, excessive for one $1.50 switch.
I've been using it since December with no apparent flames or welds to be seen.

"And wuts this doo-hicky?"

bat box fuse.jpg
"Where it can end abruptly"
(26.92 KiB) Downloaded 3 times


OMG my electrons are fused and switched before leaving the case to go on a date with the controller.


After riding for several hours in and out of fog I eventually headed home
But I wasn't done with the day yet.
I disassembled the jack shaft and added a backwards (or...reversed) 6-speed gear cage in place of my carefully-machined 13-tooth gear (LOL)
I haz the reversed freewheel blues no mo'

off with the old on with the used.jpg
just a blur of a memory now
off with the old on with the used.jpg (40.79 KiB) Viewed 241 times



re-mounting this thing is akin to a puzzle. The fog got foggiest before I could snap a pic.
Attachments
gear cage for rev freewheel.jpg
gear cage for rev freewheel.jpg (28.52 KiB) Viewed 241 times
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Sun Apr 22, 2012 2:29 am

-After the nap-

since no one's pointed out the possible flaw in this nirvana I just created... I will.

Had I bought a 'new' freewheel-adapter and geared-freewheel for the jackshaft, I would have specified a left-hand thread for both pieces.
Even my LBS has a left-hand threaded 15-tooth freewheel in their display case (and it's priced About The Same :shock: as any on-line vendor :lol:)
This particular gear-cage I just installed on the jackshaft was formerly wandering around on my EMoto's axle for the last six months, sometimes staying in one place...
-So I'm hoping it's been screwed on so tightly to it's freewheel assembly as to not pose a problem.

If it does unscrew itself I'm just gonna pin the gear-cluster to it's freewheel with a couple of steel roll pins.
If THAT fails it's task I will fall back on procuring "the right" freewheel which is "the left" freewheel.
...confused yet?

So am I.
I am ATM ~4 hours of being done (YAY) with the mechanicals of My Trike(TM)
leaving me free to build the bat-boxes and dashing dashboard

UNTIL

-finally... the dreaded Solar Panel Project rapidly approach-eth.
(sorry.. i get a lisp whenever I think about the Solar Panel Project)
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Sun Apr 22, 2012 10:03 pm

today was very interesting
And I mean "interesting" in a good/bad way with the bad outweighing the good.
First off I was reminded that it might have been awhile since I last bought clothes for myself.
Evidenced by my last pair of shorts disintegrating into piles of worn out threads :lol:
However that kills whatever funds I had available for My Trike(TM) for this month.

Good News.
Yesterday I rode for 3.5 hours with no noticeable pain, but boy am I whipped today.
I can pretty much hang up the athletic supporters since I won't be needing their support...
...because of My Trike(TM)
I used all of 2AH from the six batteries discharging 21V down to 19.84V per 5S battery.
All the batteries had the same ending voltage, which they should have beings 3Px2S should have them all about the same.
(or at least the 3P(s) exactly the same)
I have no idea how far I went, but I would guess at least 20 miles or more
Only problem encountered was a blip in the power, which today I traced to a Radio Shack fuse holder. The fuse sat loosely in the holder.
I swear the only thing Radio Shack sells that actually works good is the Euro Block connectors, although those are overpriced

...but that's the way of The Shack. *said with a western drawl*

I had some auto fuse holders left over from a different project (sourced from an auto parts store) so:
unscrew the euro block
remove crappy Radio Shack fuse holder
Insert new fuse holder and tighten the euro block screws.
-About a minute repair

Bad News Everyone! *Professor Farnsworth speaking*
The reverse freewheel experiment was an abysmal, total failure.
(my brains hertz)
but it does work as well as a fixed gear.

...try as I might... I Give Up.
"Uncle"
Time to add the fixed-gear sprocket to My Trike's(TM) rear-axle, which I hoping to avoid because it's a pain in the rear-end.
Which also means purchasing another fixed gear for the jackshaft (or rear axle. I has one I needs two)... otherwise I'll have to add a "real" idler for My Trike's pedal chain for the chain to "rise above" the gear-cluster that's currently mounted on the jackshaft
Note: the nylon thingy I added earlier to My Trike(TM) works ok as a cheap and simple chain guide, but doesn't raise the chain high enough to clear the gear-cluster's stop collar (as seen in the pictures just two posts before this post)...which has that huge setscrew and locknut thingy that catches the pedal chain (sometimes)
...yes Houston. that was yet another problem today!

...anyways a fixed gear is way less expensive than fixing an idler gear to the frame and far easier to fit.

...but procuring any new parts has to wait til the end of time
or the end of this month... whichever comes first
otherwise I would have been forced into nakedness, which would be a *very* disgusting sight indeed.
c ya
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Mon Apr 23, 2012 6:12 am

after the longest nap ever...
reflections of the day...
Awhile ago I purchased a brushed motor controller for the MY1018 motor.
It failed within a couple of days.
Before it's demise I was erked by how much noise the motor made.
However, after the controller's demise, I switched the motor directly from the 12v, 24v and 36v taps from the SLA batteries I was using and the motor became MUCH quieter.
And of course I proceeded to forget about that.
Meanwhile a few days ago I repaired the motor controller, thinking it would be the easiest way to introduce a 'soft start' function from the (yet to be built) inclonometer switch*.
So I wired up a throttle to test the motor via the controller.
Results:

-OMG what a noisy motor (like... I should care, cause I normally ride wearing a noise-canceling headset :lol:)
-The throttle curve (hall throttle) is, well, lousy... in fact it's almost an off/on type of thing.
As I'd changed the gearing of the MY1018 output to the drive axle from 5-6MPH to a top speed of about 8-10 MPH I didn't expect what happened next:
-WHEELIES!
Like the lowrider trikes My Trike(TM) resembles the front end started hopping up and down jus' like it's bigger, more scarier auto-like cousins. (because they ARE autos)

What's curious to me is this wheelie effect didn't happen when using the MY1018 with the lower speed gears (i.e torque-ier gearing) and the switched, direct-to-battery affair.
Switching a brushed motor off/on directly from a 36V battery should have had More Wheelie Potential than from a throttle-controlled controller, one would think.

Very Curious. Very Curious Indeed.

The chains stayed in their proper places today.
The problems I experienced with this new setup was the continued inability to pedal backwards**, requiring me to change a Life-Time-of-Bike-Riding-Habits if I didn't fix this situation,.
Oh, and the occasional catch of the pedal chain on the gear-cluster's setscrew. Very annoying, that.


*Yep... gonna build my own inclonometer switch because the few I found to be useful cost TooMuchMoney for the My Trike(TM) project, where money is One Big Object... due to somewhat limited and diminished funds caused by things breaking down, batteries dieing of old age, clothing expenses, blah blah blah.

**in fact, I can't imagine ever owning or riding a 'fixie' which I consider to be the Dumbest Idea of the 21Century Yet, esp. when equipped with no brakes.:shock:
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Tue Apr 24, 2012 4:46 pm

ordered a 9-tooth sprocket for a 5/8" axle from ombwarehouse... with shipping @ $11something for .My Trike's(TM) jackshaft.
Gonna highly modify the 13-tooth sprocket to fit the drive axle. Gearing should be about 10-11MPH from the MY1018 drive.
The MXUS geared-motor works fine up to about a 10% grade and just needs the assist for slopes greater than that.

Decided to use a disc brake on the un-braked rear wheel. It's the easiest to mod and provides the strongest braking solution.
Esp. as a drag brake.
-I really need a good solution for those long downhill slopes where My Trike(TM) can easily exceed speeds I'm comfortable with.
LBS has a Tektro disc brake kit that includes the disc, caliper, two sizes of caliper bracket adapters and brake cable/lever arm for ~60$...It's about the same price as online with shipping.
-although I'll have Yet Another Brake Lever Arm I Have No Use For
(gotta think of some uses for all these spare parts I'm accumulating)
(maybe I have enough for another trike LOL)

Note: The band brake works ok, but like all brakes it fades with heavy use.
+ I need the redundancy of two brakes.

The EMoto taught me that under the wrong circumstances, a band brake will fail.
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Wed Apr 25, 2012 5:09 am

hopefully my last gear system
You might notice it's simplicity compared to the previous failed attempts
Rear Drive 4 24 2012.jpg
not so easy to build as to draw
Rear Drive 4 24 2012.jpg (15.67 KiB) Viewed 398 times


I've decided to make an adapter plate for the disc brake.
A ISO 507 standard trike rear wheel is mounted on a rim spoked to a hollow hub where the hub flange has pre-drilled holes to engage the axle's drive flange.
HOLES FOR DRIVEPINS.jpg
red marks the spots
HOLES FOR DRIVEPINS.jpg (25.56 KiB) Viewed 398 times


As these hubs are the same on both the driven and non-driven wheels I going to use the drive pin holes to bolt on a homemade adapter plate for the brake disc.
I'll be re-purposing an old saw blade for the adapter plate, which conveniently has a 5/8" hole in it's center that matches the 5/8" axle
=should look something like this:
proposed adapter plate.jpg
proposed adapter plate.jpg (9.86 KiB) Viewed 398 times


Maybe I should grind down the saw teeth first?
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Sat Apr 28, 2012 5:46 pm

beautiful sunny (and windy) day!
rode My Trike(TM) for an hour or so then it was back to the shop
my shop lol.jpg
and it only takes hauling all this crap from my MH to the picnic table.
my shop lol.jpg (61.59 KiB) Viewed 381 times


Where I ground the teeth down on my newly acquired 9-tooth gear.
Then I gently modified the 13-tooth gear by cutting off it's body.
I took this photo mainly to see how much touch-up work I needed on the teeth
9 tooth on jackshft.jpg
dental work
9 tooth on jackshft.jpg (33.45 KiB) Viewed 381 times

some clean-up on the teeth is needed, I see.
new gears 4 28 12.jpg
and... done, almost
new gears 4 28 12.jpg (36.16 KiB) Viewed 381 times


I just need the energy to re-mount the jackshaft and remove My Trike(TM)'s rear axle to add the 13-tooth gear to complete this job.
...and then onwards to the disc brake.

I'm still tempted to mount the disc on the front but then there's that lil' problem of mounting the caliper, so the left rear wheel's getting the disc treatment.

Today it dawned on my feeble mind that the reason I prefer to ride My Trike(TM) over the EMoto is I don't have to fight the crown of the road. In fact My Trike(TM) handles quite like a bicycle in that regard. The fork also now self-straightens the wheel if I let go the handlebars (took some futzing with the spring tension for that effect, as any wheel mounted on an extended fork should do this)
On the other hand, the EMoto wants to drift down the crown, steering into the curb. It's actually quite a struggle keeping it on the road.
-Maybe I should procure another bent springer fork for the EMoto?
...Or maybe not.
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Sun Apr 29, 2012 9:19 pm

'nother sunny day so I rode
then I worked on the trike's infrastructure.
My back determined I wasn't ready to do much bending over so I resumed the dashing dashboard project.
dashing dashboard.jpg
...is dashing
dashing dashboard.jpg (72.41 KiB) Viewed 363 times

As I've determined I need to carry 30AH@36V (1.2KW) to go as far as I wanna go (and return) I made the decision to carry 15A worth of batteries in the DD (Dashing Dashboard).
I thought to re-examine my half-a**ed design by making the battery enclosure easy to completely remove from the DD.
Using my super accurate methods of drilling holes *lets the drill bit skip until it bites* I started in.
In the beginning I proceeded to mis-measure and mis-cut my large chunk of aluminum L-channel ...luckily catching the error during the dry mock-up of the cut parts. I had exactly just enough channel left to make the right lengths (a minor gift from the gods of DIY)
meticulously measured LOL.jpg
HahahahaHA
meticulously measured LOL.jpg (30.72 KiB) Viewed 363 times

Removing the two 1/4" bolts will allow the battery cage to slide out of the DD
although the DD is hardly symmetrical it was easy to make all the end panels line up by surgically removing excess material with a belt sander loaded up with the coarsest of sanding belts
beltsanders fix anything.jpg
...for maximum slop
beltsanders fix anything.jpg (23.66 KiB) Viewed 363 times

I definitely caught too much sun *he says with A RED FACE*

The day ended before the project got completed.

The last couple of days has had my solar system delivering all of 600W. Hardly a good performance from a 200W system.
I raised the panels up for the first time this year and results were disappointing. I expected at least 1KW per day.
-something else to fix.
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Mon Apr 30, 2012 9:31 pm

been raining and foggy all day but here at 7:30PM the sun broke thru.
-too late to do anything.
So this month (or two) I need to purchase another 8 5S 5000mah batteries to effect my fantasy rides

...and if I'm gonna fantasize I can fantasize this:

4 wheel fantasy.jpg
going where I've ridden before
4 wheel fantasy.jpg (44.74 KiB) Viewed 349 times
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Tue May 01, 2012 9:14 pm

almost finished the bat box for the DD
need to add the connectors and Velcro strapping and then complete the rest of the DD

Taking the battery assembly out of the DD finds that it fits nicely in the BigBlackCase
-meaning I should build another one for two of them. Maybe three, but the MY1018 motor/controller is only to be powered from a 36V 10AH battery (4x 5S) so the bat box could be different...or not.
bat box side.jpg
bat box side.jpg (55.73 KiB) Viewed 337 times
bat box tupoff.jpg
bat box tupoff.jpg (38.79 KiB) Viewed 337 times
bat box top.jpg
bat box top.jpg (41.11 KiB) Viewed 337 times
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby docnjoj » Wed May 02, 2012 4:01 pm

Hey DDK
I'm afraid someone beat you to the "Fantasy Quad". It is an actual bike by Lightning Recumbents. Lotta money though! Keep on writing as I really like your stuff!
otherDoc

Lightning Phsntom Quad.doc
(26 KiB) Downloaded 22 times
E-bike stable at our house
Bike-e electric front brushed C/L
Steintrike Mad Max full suspension trike rear 9C
Sun USX delta trike 9C front wheel sort of front suspension
Frame of homebuilt trike in shed with Bafang still on it
New Agniusm/A123 on the Steini and old 10ah Ping paralleled with 12 ah Fatpacks on USX
My wife and I ride the trikes
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Wed May 02, 2012 4:36 pm

docnjoj wrote:Hey DDK
I'm afraid someone beat you to the "Fantasy Quad". It is an actual bike by Lightning Recumbents. Lotta money though! Keep on writing as I really like your stuff!
otherDoc

The attachment Lightning Phsntom Quad.doc is no longer available

:lol: that's just a bicycle with adult-sized training wheels!
bent with training wheels.jpg
one-wheel drive vs three-wheel drive
bent with training wheels.jpg (62.03 KiB) Viewed 322 times


my fantasy quad incorporates 3 motors with invisible batteries suitable for climbing the Cascades from east to west into Seattle
and other, similar rides. :)
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Wed May 02, 2012 6:42 pm

-stopped in at Radio Shack to get more stuff (euro blocks and banana connectors)
thank goodness they didn't have all I needed so Surf's Up!
Futerlec sells the same euro terminal blocks for $2 that RS sells for $6.something.
same deal with the banana connectors
-BUT- (bigger than but)
...while ordering the banana connectors for the battery box(s) from Futerlec:
I stumbled upon a connector I stupidly forgot about:
http://www.futurlec.com/Speaker-Terminals.shtml
speakon line.jpg
4-pole 30A per pole
speakon line.jpg (7.34 KiB) Viewed 320 times

Speakon connectors are used for high-power amplifier connections up to 1000w and have 2-8 poles which can accept up to 10g wire. The contacts are rated for continuous 30A each.
Neutrik, the original designer of these connectors specifies they are not to be used for power connections, just like phone plugs and 3-pin XLR connectors shouldn't, but are, used. LOL
They're relatively inexpensive and are locking connectors. The 2-4 pole connectors are terminated with a set screw (easy and secure) or soldered (pain-in-the-ass with 10g wire)
I'm jus' gonna use these bad boys as bulk charger connectors for the bat boxes
speakon chassis.jpg
On front panel of DD
speakon chassis.jpg (16.94 KiB) Viewed 320 times
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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Re: My ultra-sufficient semi-recumbent tricycle project

Postby ddk » Thu May 03, 2012 4:14 pm

it's another rain and fog day
I've drilled and mangled my one folding table enough that I no longer bring it into the MH, leaving me work surfaceless.
That only leaves me to design other parts of the puzzle yet to be decided upon.

so today's design (that will likely change) is the inclonometer switch for the MY1018 motor/controller

the requirements:
I can't climb grades that approach 15% with only myself and the front hub motor doing the work.
That is, without risking melting down the front hub motor (and myself for that matter)
I would like a hands-off approach because I'm generally doing things like... steering and... changing gears (see- I SHOULD HAVE bought the nuvinci hub solution!)

the fundamentals:
this image was borrowed and cropped from the en Wikipedia from a discussion on road grades
road rage or grade.jpg
where things get slopeiest
road rage or grade.jpg (19 KiB) Viewed 311 times


so the switch should operate with about a 7 degree angle
inc switch.jpg
somewhere between 6 and 8 degrees so prolly 7
inc switch.jpg (31.1 KiB) Viewed 311 times


as one might discern from the images; it wouldn't take much of a bump to accidentally activate a switch activated by a swing arm.
My limited mental capacity limits me to think about using either:
-some sort of time-constant to activate a comparator circuit. (simple to design... but*)
-some sort of dampener on the moving lever arm that activates the switch (too much futzing and would likely never work right all the time)

*old age sux- I can hardly see a minidip package much less hold one with my shaky hands, which also makes soldering a circuit board pretty much a thing of the past.
This is probably for the best... as I've likely sucked up MUCH more than my fair share of lead fumes over the years leading to my current mental-state-being-a-derp

after perusing the interwebs for info I think I can just dampen the movement of The Pendulum by lengthening it's arm, increasing the scha-wing before it hits da switch-thingy
Edger Allan Poe would be happier if I had a blade attached to the end of the pendulum, but I'll use a hammer.
"Au contraire, mon frere"
"The more you pay for a bicycle part, the harder it is to install" Mr Contrary, formerly known as "wishey-washy-wobbly"
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