Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

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Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby amberwolf » Tue Jan 26, 2010 4:51 am

Ran across this thread on DIYEC:
http://www.diyelectriccar.com/forums/sh ... 41164.html
with this "electric transaxle" diagram:
The Electric Transaxle STI_ST58.jpg
The Electric Transaxle STI_ST58.jpg (81.31 KiB) Viewed 1243 times


I am wondering if two hub motors plus a Sturmey-Archer internally geared hub would work for this, if taken apart and suitably modified and put back together? Or some other planetary gear drive?

I have set my brain on "ponder" so it can figure out if I have other things laying around here that would allow this idea to be tested in a small enough configuration to be useful on a cargo bike. :)
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby amberwolf » Tue Jan 26, 2010 5:16 am

Just had a thought. Take a bicycle hub motor and build a sun gear on it's outrunner casing.

Take an F&P washing machine motor and machine out the core of it's stator so the above would fit inside it with clearance for planetary gears and a ring gear, plus bearings for the stator to ride on (like little planetarys) between the stator and the ring.

Then the rotor would be remachined so it rides on the ring gear.

Carrier for the planetaries gets welded or otherwise fixed to the former long axle of the F&P motor. Suitable bearings for the rest of everything to ride around these.
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby amberwolf » Tue Jan 26, 2010 5:22 am

Oh, and the hub motor would need to have it's axle changed to a larger hollow tube with larger bearings for the original casing to run on, and smaller bearings inside the tube for the F&P axle to run inside of.
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby Miles » Tue Jan 26, 2010 5:26 am

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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby amberwolf » Tue Jan 26, 2010 5:34 am

Thanks! I missed that in my brief search. :oops:

I don't see a resolution to it yet, so I will link this thread there. Maybe between all of us we'll get one that is easy to build and testable. :)

I think I would love to have something like this, even a kluged up version like what I described above. If I had any way I could think of to make the sun and ring, and use planetaries I might already have around here (just a bunch of identical gears, as many as I could find to carry the load better between them), I would see if I could get hold of one of those F&P motors as a ring motor to try this out, using the cieling-fan motor Karma is rewinding as the sun motor.
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Re: eCVT

Postby Miles » Tue Jan 26, 2010 5:50 am

The F&P motor is an outrunner... :wink:
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Re: eCVT

Postby amberwolf » Tue Jan 26, 2010 5:54 am

Yes, it is, which is why it has to be cored out so that a ring can be affixed to the rotor that would carry the ring gear. :)
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby Miles » Tue Jan 26, 2010 6:02 am

I don't see the connection but I'm a bit slow today :)

I'm not sure about "coring out" a rather flimsy plastic moulding..........
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby liveforphysics » Tue Jan 26, 2010 6:38 am

Miles wrote:I don't see the connection but I'm a bit slow today :)

I'm not sure about "coring out" a rather flimsy plastic moulding..........


Amberwolf is capable of de-coreing an F&P motor with a discarded pearing knife, just like it was an apple. Then thermo-forming back together used zipties he pulled out of a dumpster, and mounting planetary gears carved from the lids of jars with them. They would circle the perimeter of a hubmotor made from a used aluminum pie pan and a stack of pennies with HD magnets glued to it. Then he sets up independent throttles on them, and he can set the difference in throttle positions to determine the effective gear ratio. Duh Miles! ;) ;) ;) ;) ;) ;)


I'm just teasing you of course Amberwolf :P :P . I admire your resourcefulness and spirit, and respect your willingness to jump-in and try things, and very impressed that you've made effective transportation for yourself while having minimal environmental and financial impact. Much respect for you and your methods Amberwolf.
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby Miles » Tue Jan 26, 2010 6:43 am

:mrgreen:
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby amberwolf » Tue Jan 26, 2010 3:21 pm

Miles wrote:I don't see the connection but I'm a bit slow today :)
I'm not sure about "coring out" a rather flimsy plastic moulding..........

I'll probably have to draw up a sketch. Google Sketchup sucks for almost anything that requires actually lining stuff up in it, so I am going to go back to my Lightwave3D to do it--takes longer but at least it works exactly like I tell it to. (I could rant for pages about Gurgle Scatsup's issues but I think it would be pointless.)

This might not work at all, due either to materials or concept, but:

Basically, imagine a big pipe, the kind that's intended to bolt to another one end to end. So you have a ring of bolt holes on a flange, and a cylindrical ring that is attached to the inner circumference of that. Imagine that with the flange bolted to the rotor's flat side, and the cylinder fitting just inside the minimum remaining amount of stator material, with bearings between them to support the rotor in rotation/etc.

It would be better to use an inrunner, but I don't know of one that's big enough to surround a planet carrier that surrounds another outrunner that itself is big enough to surround a shaft and bearings, all of which could be found for little to no cost (with just the labor of rewinding them to whatever necessary speed/torque). The F&P happens to be quite large inside the stator, and could fit a number of different outrunners inside it. :) At least, as far as I can judge from pictures I've seen, primarily from the F&P Motors thread.

It might end up necessary to build an entire double-cylinder with flat endplate flange connecting them, to entirely replace the F&P rotor, but I'd rather not go there if it's not absolutely necessary. ;) It'll be hard enough finding the right piece to make the inner cylinder/flange from, much less one that happens to be exactly the right diameter to allow the magnets to ride exactly where they did in the plastic one.

Then there also has to be connecting structure between the stators of both motors, in such a way as to not interfere with their rotors or the planet carrier or output shaft.

I'm absolutely sure it would be better to design this from scratch and build it from purpose-made parts...but that would probably be less of a challenge to make it work, and very few people could actually build one that way. :) If there is a way to make it from recycled parts, then it might be possible for a lot more people to build one of their own, if they are of a mind to. Can you imagine Naeem's bike (or my CrazyBike2) using this instead of all the vulnerable chain and sprockets? Neither of us would have problems shifting anymore, or the kinds of chain issues that come up from using unenclosed chains in environments that are virtually guaranteed to destroy them eventually, if not quickly. ;)


liveforphysics wrote:Amberwolf is capable of de-coreing an F&P motor with a discarded pearing knife, just like it was an apple. Then thermo-forming back together used zipties he pulled out of a dumpster, and mounting planetary gears carved from the lids of jars with them. They would circle the perimeter of a hubmotor made from a used aluminum pie pan and a stack of pennies with HD magnets glued to it. Then he sets up independent throttles on them, and he can set the difference in throttle positions to determine the effective gear ratio. Duh Miles! ;) ;) ;) ;) ;) ;)

Well, actually.... :)

Not for this project, but I *have* looked at finding ways to melt down and reuse the nylon zipties, since all the ones I can find made in the last 15+ years have been garbage that break when I actually tighten them down, or they rot apart with a week of riding in the sun (sometimes longer if they're not white/clear). That's a lot of nylon, and I could use the stuff to mold into discs to make standoffs, chain guides, or bushings with. ;) Maybe it wouldn't disintegrate if it were in thicker chunks. :roll:

Pennies wouldn't work too well since they're mostly zinc with maybe a plating of copper, unless I found enough older ones, and I'd probably rather use pizza pans rather than pie pans because some pizza pans are actually pretty thick and stiff. :P Or saucepans since they can be nice thick aluminum and very stiff. Unless I make a foundry for recasting the pie pans into stuff, like Thud and FrankG do (though I actually have a pile of harddisk casings saved for this purpose once I have the time and the money to spend on the furnace part).

Though really the sun motor would be made from a cieling fan. ;)

And the independent throttles is something like what I would do, although I figured a stereo balance pot out of an old audio amplifier for a single throttle control would be better. Then it would have a center position to use for 1:1, and then as I turn it to one side or the other it would run one motor faster and the other slower. There are probably better ways to do it but this is fairly simple in execution, uses a recycled part, and ought to work. :)

Of course, each controller's throttle input would need to be calibrated for the motor it is running so that at center throttle each spins at the RPM needed to maintain zero output on the shaft.

I'm just teasing you of course Amberwolf :P :P . I admire your resourcefulness and spirit, and respect your willingness to jump-in and try things, and very impressed that you've made effective transportation for yourself while having minimal environmental and financial impact. Much respect for you and your methods Amberwolf.

Oh, I know you're teasing. :P There are those that aren't teasing but they usually say things differently (sometimes it's hard to tell but in print I can usually tell. In person my AS generally makes it very very hard to tell unless I know someone well, and even then...).

As to the "effective transportation", well, that's only when I don't break bits off of it from stupid ideas or poor construction methods, or my apparent geometry-perception problem that seems to make it impossible for me to make straight lines and square lineups, even using the proper tools to measure such things. :( You know, "measure twice, cut fourteen times". :P
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby Miles » Tue Jan 26, 2010 3:36 pm

amber,

It's a great idea, I'm just a bit sceptical about the suitability of the F&P motor, that's all. It seems to be a rather low grade motor, primarily designed to be made very cheaply and looks as if it would be tricky to modify successfully. Its size seems to be the only thing going for it.

There again, there's nothing much to be lost from trying :)
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby amberwolf » Tue Jan 26, 2010 4:04 pm

In my experiences so far, it has been easier to make some things from scratch rather than modify cheap ones. But some of them are outside my abilities to make, and large perfectly-round objects are among them. ;) Kinda need that for a rotor/stator to work right, so I generally just try modifying things instead, even when they're not particularly suitable. :roll: Often enough it ends up not worth the time I put into it but I certainly learn a lot. :)

Sometimes I end up with the same final product design (but not able to make it) as some commercial product, after I revise and fix and revise and fix. One example is one of the cargo bike ideas I have--it basically always boils down to a slight variation on Justin's cross-Canada bike, to make it work out with as little actual work as possible to do to make it. It started with the CrazyBike2 (which kind of looks like his but isn't made the same way) and evolved on paper many times down to that same basic idea he used. It's just easier. :)

Also, sometimes I get excited about an idea because I can see a way to make one for myself (when I know I can't ever buy one for whatever reason), but it doesn't mean that it's a *good* way. ;) I have certainly had more than my share of zingers. but as I say: I learn a lot. :)
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby docnjoj » Wed Jan 27, 2010 6:07 pm

Also, sometimes I get excited about an idea because I can see a way to make one for myself (when I know I can't ever buy one for whatever reason), but it doesn't mean that it's a *good* way. ;) I have certainly had more than my share of zingers. but as I say: I learn a lot. :)[/quote]

I believe that learning a lot is what genius is all about, Amberwolf. I don't possess it but I think I can recognize it when I see it! Keep up the great work.
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Re: Infinitely-variable-ratio CVT from 2 BLDC + Planetary?

Postby amberwolf » Mon Feb 01, 2010 9:13 pm

Well, it looks like while this type of unit might be a *form* of IVT, it does not actually allow for different ratios for torque conversion. Meaning, it is indeed a variable-speed unit, but it is not variable-torque, in any traditional way.

Whatever the torque input is from the motors will be summed and presented at the output. So you'd still need high-torque motors on either end of the shaft (the sun and ring gears), to get good torque out of the planet carrier.

It does still allow you to spin both motors at very high speeds while keeping the output shaft at a very low speed, but that's all. I guess it would really be only good for if you had two motors that were half the torque you needed, you could connect them both with this device and drive one output. But there are other methods to do that.

Here's the original thread with the info, on DIYEC. Link starts at end of relevant part of thread, you can read upward from there if you want to see how the discussion reached that point.
http://www.diyelectriccar.com/forums/sh ... post164318

Also crossposted this to the other IVT thread.
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