Miles' Project 1 [eMoulton]

[Miles]

Moulton TSR conversion

[Miles]

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

[Miles]

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



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:

[TylerDurden]

HUB-BA!

Drool.

wolf1.gif (101.94 KiB) Viewed 21149 times

[dirty_d]

wait did you make this?

[Miles]

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/

[Malcolm]

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

Is the rear belt sprocket custom made?

[EMF]

WoW! 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!

[Miles]

Hi Malcom.

Thanks.

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

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

[Miles]

Thanks EMF,

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

[paultrafalgar]

Awesome, Miles! So that's what you meant, here:
viewtopic.php?f=2&t=953&p=65808&hilit=+working+on+it+#p65808

[paultrafalgar]

Give us references for those parts, please, particularly the motor. Googling for it don't find anything. Thanks.

[Lessss]

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.

[scottclarke]

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

[Miles]

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....

[deecanio]

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

[Miles]

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.....

[Miles]

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

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

[Miles]

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.....

[Miles]

Last shot of the session:

[docnjoj]

Wow Miles!!!!!That is simply gorgeous! The workmanship is superb! I'm speechless, especially after my bodging!
otherDoc

[tropmonky]

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

[Miles]

Thanks guys,

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

[Miles]

Battery pack:

[deecanio]

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