Miles' Project 1 [eMoulton]

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Miles
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Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 5:47 am

Moulton TSR conversion
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eMoulton5-(800-pixels-w.).jpg
eMoulton5-(800-pixels-w.).jpg (149.8 KiB) Viewed 21080 times
eMoulton1-(800-px).jpg
eMoulton1-(800-px).jpg (151.18 KiB) Viewed 20578 times
eMoulton2-(800-px).jpg
eMoulton2-(800-px).jpg (146.48 KiB) Viewed 20578 times
eMoulton4-(800-px).jpg
eMoulton4-(800-px).jpg (168.16 KiB) Viewed 20578 times
eMoulton8-(800-px).jpg
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Last edited by Miles on Sat Jul 19, 2008 3:39 pm, edited 6 times in total.

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 5:47 am

Moulton TSR27 bike

-Planet Ryder brushless motor.
-Dual-Drive hub gear (4 derailleur sprockets retained).
-Freewheeling crankset.
-Gates Powergrip 8M GT3 belt transmission (16t to 100t).
-Sprague clutch in hub of rear pulley
-NiCad power tool batteries 36V 4Ah (provisional), in backpack.

-Weight (without battery) 16.5 kg (36 pounds)

Antecedents:
http://www.solarnavigator.net/electric_cycles.htm (Aloha Randy!)
http://v3.espacenet.com/origdoc?DB=EPOD ... =US3280932
http://www.electric-bikes.com/bikes/charger.html
Last edited by Miles on Fri Jul 18, 2008 5:04 pm, edited 17 times in total.

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 5:47 am

Here's a pic of the inside of the motor:

Image

Published spec.

Motor

Ke = 17 V/kRPM

Kt = 0.17 Nm/A

Resistance 0.25 Ohms

Inductance (approx.) 200 uH

12 Poles


Controller

Nominal input voltage 16-48V (max. 55V)

Continuous output current 20A

Peak output current 35A

Output power (max.) 1 kW



Measured no-load current of motor

0.8 A @ 38V


3D model PDF:
Attachments
E-bike motor.pdf
(1.26 MiB) Downloaded 2042 times
Last edited by Miles on Sun Jul 13, 2008 4:28 am, edited 6 times in total.

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TylerDurden
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Re: Miles' Project 1 [eMoulton]

Post by TylerDurden » Sat Jul 12, 2008 8:06 am

HUB-BA!

Drool.

wolf1.gif
wolf1.gif (101.94 KiB) Viewed 35501 times
Have a Nice Day,

TD

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Re: Miles' Project 1 [eMoulton]

Post by dirty_d » Sat Jul 12, 2008 9:06 am

wait did you make this?

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 9:18 am

Tyler - hehe.... Thanks.

dirty_d - I didn't make the bike itself, I just did the conversion to an ebike.
http://www.tsr.uk.com/bikes/

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Malcolm
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Re: Miles' Project 1 [eMoulton]

Post by Malcolm » Sat Jul 12, 2008 10:53 am

It was worth waiting for Miles. Tis a thing of beauty.

Is the rear belt sprocket custom made?

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Re: Miles' Project 1 [eMoulton]

Post by EMF » Sat Jul 12, 2008 10:59 am

WoW! :shock: Well done! That is one of the best conversions I have ever seen. Love the belt drive. It must have taken a lot of thought and pre-preparation to have this bike come out so nicely. The way the belt slips inside the frame, yet misses the tire and the brake is a fantastic fit. Very clean design all the way around. Kudos! 8)
Last edited by EMF on Sat Jul 12, 2008 11:01 am, edited 1 time in total.

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 11:00 am

Hi Malcom.

Thanks.

The pulley itself is from the Strida 5 :wink:
I had to re-machine it a bit, though.

The pulley hub, which contains the clutch, I had to make myself.

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 11:03 am

Thanks EMF,

Yes, there wasn't much clearance for the drive in any direction :)

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Re: Miles' Project 1 [eMoulton]

Post by paultrafalgar » Sat Jul 12, 2008 12:31 pm

Awesome, Miles! So that's what you meant, here:
viewtopic.php?f=2&t=953&p=65808&hilit=+working+on+it+#p65808
If we knew what it was we were doing, it would not be called research, would it? Albert Einstein
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If the greatest pleasure is giving, be selfish - give pleasure.

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Re: Miles' Project 1 [eMoulton]

Post by paultrafalgar » Sat Jul 12, 2008 12:38 pm

Give us references for those parts, please, particularly the motor. Googling for it don't find anything. Thanks.
If we knew what it was we were doing, it would not be called research, would it? Albert Einstein
A paranoid is someone who has SOME idea of what's going on. Allen Ginsberg(?)
If the greatest pleasure is giving, be selfish - give pleasure.

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Re: Miles' Project 1 [eMoulton]

Post by Lessss » Sat Jul 12, 2008 1:19 pm

Awsome. It just needs fenders to keep the road rain off the motor controller and your set.

Interested to see how and where you decide on battery placement.
Give me nuclear batteries I say!! Ripped off by Joshua Goldberg to the tune of almost $900 re headway groupbuy for batteries, no $ no batteries
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Re: Miles' Project 1 [eMoulton]

Post by scottclarke » Sat Jul 12, 2008 1:24 pm

First class Miles - very very neat. Reckon you had as much fun as I with clearances!

The motor - you mention Randy - is that the troublesome fella from Hawaii? If so - has he commercialised his motor? This looks a lot bigger than the one he was using???

Scott
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1 off 2.8KW Marin Trail full susser + all RC gear - very light!

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 1:39 pm

Hi Paul,

The motor was made in a small batch only, a few years ago. It never went into production, I'm afraid.

The 16t 8M motor pulley was a custom job, the smallest commercially available is 22t and the smallest recommended size is 18t, but it works fine..

The 100t rear pulley is from the crankset of the Strida 5 bicycle - you can buy the whole crankset as a spare part.

16t to 100t is only 6.25:1, though...

To get a greater reduction ratio, in a single leap, you have to move to 5M size belt, but this means a completely custom large pulley.... 5M pulleys are available down to 12t but 16t is probably the smallest of any use in a one step drive.

Probably a good compromise between torque transfer, reduction ratio and size would be to use 18t to 180t 5M (10:1)

An alternative for less powerful drives might be to use a 100t belt as a tyre on the Strida pulley and run it as a toothless pulley with a 5M belt. This would give 18t to approx 162t (9:1). I've only tested this on the workbench so far, though....

So, there are various possibilities in terms of pulleys.

It would be fun to put together a kit of parts if there was some kind of concensus as to what people want....

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Re: Miles' Project 1 [eMoulton]

Post by deecanio » Sat Jul 12, 2008 1:54 pm

Hi Miles,

beautiful work :)
cant wait to see this bike in action, instantly in my top 3 at the mo with recumbants and scotts.


Cheers


D
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 1:55 pm

Less,

Yes, need to make some mudguards, for sure.

I'm quite happy having the batteries in a backpack, for now. It keeps the bike weight down to within the range of normal bikes, so I can easily carry it up the steps to my house. Also, it handles pretty much as it did before I converted it.

The obvious place for the battery, if you moved it to the bike, would be to hang it behind the rear seatpost. You could have an auxiliary battery on the steerer tube. Adding batteries to the central framing would kind of detract from the elegance.....

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 2:01 pm

scottclarke wrote:First class Miles - very very neat. Reckon you had as much fun as I with clearances!

The motor - you mention Randy - is that the troublesome fella from Hawaii? If so - has he commercialised his motor? This looks a lot bigger than the one he was using???

Scott


Hi Scott,

Yes they don't make bike frames with us in mind :lol:

Southwestern Windpower made a small batch of motors, supposedly to Randy's spec. It never got any further than that...

Maybe the motor looks bigger because my bike has smaller wheels :)

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sat Jul 12, 2008 2:09 pm

Thanks D

I'll see what I can do re. video.

Feel free to call in, if you're ever around SE London.

Wait until I've got a decent battery, though.....

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Sun Jul 13, 2008 3:25 am

Last shot of the session:
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Re: Miles' Project 1 [eMoulton]

Post by docnjoj » Sun Jul 13, 2008 2:52 pm

Wow Miles!!!!!That is simply gorgeous! The workmanship is superb! I'm speechless, especially after my bodging! :mrgreen:
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Re: Miles' Project 1 [eMoulton]

Post by tropmonky » Sun Jul 13, 2008 6:40 pm

docnjoj wrote:Wow Miles!!!!!That is simply gorgeous! The workmanship is superb! I'm speechless,


I second this! Wow, very very clean! I bet this will last a long time to!

Kyle

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Mon Jul 14, 2008 12:59 am

Thanks guys,

It just wouldn't look right to use "duct tape style" on a Moulton :mrgreen:

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Miles
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Re: Miles' Project 1 [eMoulton]

Post by Miles » Mon Jul 14, 2008 5:17 am

Battery pack:
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Re: Miles' Project 1 [eMoulton]

Post by deecanio » Mon Jul 14, 2008 6:38 am

Hi Miles,

yes, very very nice indeed - im with you to have the packs onboard would detract slightly from the bikes elegance.
If im in and around s London i'll give you a bell - likewise let me know if your in Loughton area and we'll hook up - to be honest with you in se london me in essex, knoxie in oxford and Joz in brighton i figure we could all meet before the season is out?
Im just waiting ( and not hassleing at all ;) ) for Joz to make up my custom packs - he should be done soon but i will probably be away when it's ready :( so it's looking like i wont be able to go get it until the 2nd August.i dont know if we have missed the forest of dean meet but i'm sure we could all get together at some point?
Again, lovely job miles, she's a minter!!!!


Cheers


D
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