RIPPY SCOOT

[RIPPERTON]

So I swapped my electric kart for a new Kelly controller...... I know right.
But it blew up before it ever turned a wheel as the config program had a booby trap in it.
Kelly wont replace it under warranty. Giving Kelly a big miss from now on.
So what do you guys think of Golden Motor controllers.
I got a quote of $1136 aud shipped for a EZ-B144400 180v 400 A phase sine wave.

 

[RIPPERTON]

Deal Breaker alert !!
Despite the Golden Motor chatbot telling me twice that this controller has variable regen control... it actually doesnt.
I always use a 0-5v pressure transducer mounted in a hydraulic master cylinder on the handlebars to control regen full time all the time. Its my standard service brake. Hydraulic disc brakes only get used in emergency.

 

[RIPPERTON]

So no replacement ctlr from Kelly. I decided to use one the 600A KHB,s from the R1 race bike. It had 2 of them siamesed together in one housing with copper heat sinks. Just had to separate them and modify the housings.
That all worked out and it ran great.....for a while, then the hub motor dropped some of its magnets and blew a wad of molten smokey stuff out of the vent holes.
was on the way to the post office all downhill and never went past 1 third throttle. Had to walk home and get the van.

 

[RIPPERTON]

Wonder what could have broken the stator laminations.
I think a small rock got in through a vent hole.
Ferro Fluid is still there as brown liquid stuff in the stator grooves.

 

[RIPPERTON]

Got the new QS 12kW hub motor at 11kv makes about 2000rpm at 175v.
Resisted the temptation to take the motor apart and modify it with cooling holes
but did drill and tap an M8 hole out near the rim to inject Ferro Fluid.
This hub motor is pretty good and doesnt get over 65C at least in winter.

 

[RIPPERTON]

The motor came with steel axle locks which no matter how tight the nuts are will
always move back and forth going from power to regen. So CNCd up some 16mm alloy axle clamps.
And stuck a thermometer sticker on.

 

[RIPPERTON]

Then did a big range test run and got 280km out of 1 charge. 6 hours of run time.
I set the Kelly minimum battery voltage to 125 but I have never used this function so didnt know how it would act.
I got down to about 130v and the throttle started to have no response and thought crap ive blown the cells...but.
turns out the Kelly was ramping down power and each cell was only at 3.1v which was fine.
Lowest cell voltage according to the manufacturer was 2.75.
Brought it home and set the chargers onto it overnight. 9 hours later it was back up to 176v.
You just cant get range anxiety on this bike.

 

[dominik h]

These steel axle locks are crap. I had the same problems with my 8kw Erider motor. Going from 12kw to 3kw regen and back to power.
I like your solution.