RIPPY SCOOT

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RIPPERTON   100 W

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Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Nov 18 2021 9:29pm

CNC'ing the busbars and clamps. Also planning the battery management connections to the busbars.
Made a dummy end frame to se if it fits in the battery box. The first example didnt fit because the
box isnt perfectly straight all the way down, gets narrower so had to make the frame smaller.
Used the thread tapping machine to tap 200 threads in the clamp bars.
The red insulation tape on the busclamps stops chafing and props the bar out toward the tabs so the screws start easily.
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Nov 21 2021 10:13pm

This is the inside face of the end frame for the front pack.
The loopy groove is for a silicone tube that will be pressed against the surface of the busbars.
I couldnt find any silicone tube with high thermal conductivity so bought a standard food grade tube with 7mm OD and 1mm wall thickness (very thin). I will size the groove so the tube will get squashed into a D shape. This rad / fan should fit under there somewhere.
This build might be lower performance than the Kart but I learnt that a cooling system is better there even if you dont need it.
Attachments
FRONT FRAME.jpg
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Nov 25 2021 6:45pm

When only the best will do....Batrium battery management systems.
These Longmons and harness came off the race bike last used in 2016.
Trying to make a scramble of wires look sensible is a challenge.
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Nov 25 2021 9:37pm

Moving along to the cooling system. Experimental trough design.
Il have the one on the left except 4.5mm deep.
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RIPPERTON   100 W

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Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Nov 26 2021 10:02pm

3 different tool paths for the end frame.
6mm Bull Nose for the internal corners.
6mm End Mill for the area clearance and blind holes
4mm End Mill for the small holes and outside.
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Nov 28 2021 11:32pm

Front pack is in, tight fit. Each cell block is mostly supported by its tabs as they are quite stiff.
There a small gap designed between each block but there will be a bit of sag. Important is the bottom block does not support the weight of the whole pack.
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RIPPERTON   100 W

100 W
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Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Nov 28 2021 11:34pm

Rear pack is 24s 2p 37kg.
Wooden frame to make sure all bolts can line up.
Also helps when tightening so the tabs dont get tweaked
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Dec 01 2021 3:27pm

Got this 120mm radiator off EBay. Like folding the other radiator in half. $24
The rear pack has cell number 21 in it. Thats half way through the whole pack and where I want to attach 2 small cables for the 87v kart chargers. These are small chargers that I can pack into the helmet bin for destination charging.
Problem is getting those cables out amongst all the management wires.
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Dec 01 2021 7:08pm

Found these M4 lugs that will fit under the acetal cover and run 10A wire out.
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Dec 01 2021 7:10pm

24 Batrium Longmons wont fit lying flat so have to rack them standing up. They are 2.5mm thick so have to jog the toolpath for the 3mm end mill so the acetal frame grips them a bit.
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RIPPERTON   100 W

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Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Dec 13 2021 2:55pm

Rear pack is built. Will check airgap under the bottom cell in a few days.
Will also bench test BMS system before final install.
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Dec 22 2021 3:22am

Batrium BMS system is up and running....on the kitchen table.
All cells are either 3.74v or 3.75v factory shipping voltage.
The BMS system is re used virtually as is from the race bike last run in 2017.
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Jan 22 2022 5:17am

Both packs in and charging with the old R1 Elcon charger at 22A.
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Jan 22 2022 11:20pm

Original phase cables wernt long enough to reach ctlr so 3 short cables down to the originals which are awfully skinny lookin.
And an acetal insulator box clamp standoff thingy with 4 M4 screws whipped up in 40 minutes.
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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Jan 24 2022 6:29am

First run.
Motor seems to be wound tall ie low turn count in the coils. Doesnt take off very fast from standstill but accelerated well from 40kmh onwards.
https://studio.youtube.com/video/SaWz11n4E_M/edit

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Dui, ni shuo de dui   10 kW

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Joined: Jan 29 2016 3:21am

Re: RIPPY SCOOT

Post by Dui, ni shuo de dui » Jan 26 2022 3:28am

Awesome build, your battery design is great :bigthumb:
I especially like the idea you had to tilt all the little balancing PCBs to gain space, small detail but very neat.
:bolt: New Build in Progress: Electric Roadster, 30 000W Kelly KLS72701, 24S2P A123 cells :bolt:
viewtopic.php?f=12&t=109246

:bolt: My electric Ninja 250 clone: 16 000W Sabvoton 72200 Unlocked, 23S2P A123 cells : :bolt:
viewtopic.php?f=12&t=90032

:bolt: My electric Scooter: 16 000W Sabvoton 72200 Unlocked, 72V 20Ah 24S1P A123 cells: :bolt:
viewtopic.php?f=12&t=75912

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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » Jan 26 2022 5:31am

Thanks Dui.
Im having problems with the controller, its not powerful enough or is going to blow up soon.
I have 2 300 amp versions of this and will try one of them.
Ultimately it should have a sinusoidal unit so if anyone knows of a good ctlr other than Kelly 175v 300A let me know

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RIPPERTON   100 W

100 W
Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » May 14 2022 11:44pm

After bothering to invent a new way to Pre Charge Boot the scooter with momentary buttons, one to the precharge both the ctlr caps through a resistor and power up the DC-DC 12v supply which energises the main contactor after 10 seconds and another one to disconnect the DC-DC 12v to shut the whole system down, I just went with 2 rocker switches instead.
The ctlr caps can be powered down for long storage so no drain. Switches hanging out will be fitted later.
No Batrium atm but the 2 kart chargers are pumping up to 24A which is as much as the 4kW Elcon charger and half the size.
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charger.jpg
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PreCharge.jpg
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RIPPERTON   100 W

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Posts: 186
Joined: Feb 26 2013 11:44pm
Location: Sydney Australia

Re: RIPPY SCOOT

Post by RIPPERTON » May 14 2022 11:53pm

Went for a 20km ride today and the scoot performs well.
The motor is wound tall and doesnt get off the mark very quickly but at around
60kmh any throttle shows this scoot has plenty of legs.
At 2 and a half times the original battery voltage and more than double the ctlr current the motor gets very hot and doesnt cool down after stopping. Its a big chunk of unventilated metal and as predicted will need modifying.
The ctlr gets hot too and will probably get the fan/radiator that was intended for the battery pack.
Top speed in the burbs today was 105kmh (not flat out).
Also got a 19mm brake master cylinder for the integrated disc system that works well.
The original MC was 14mm and had too much travel with both calipers.
The 19mm MC isnt exactly double the diameter but works with acceptable lever travel and very powerful.
The regen function cuts out at about 10kmh so need the discs to stop at lights.
Attachments
1st run.jpg
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19mm MC.jpg
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Elektrosherpa   100 W

100 W
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Joined: Feb 07 2021 8:19am

Re: RIPPY SCOOT

Post by Elektrosherpa » May 15 2022 3:51am

RIPPERTON wrote:
May 14 2022 11:53pm
... the motor gets very hot and doesnt cool down after stopping.
...
The ctlr gets hot too and will probably get the fan/radiator that was intended for the battery pack.
...

Would be interested to know what temperature you call "very hot" resp. "too hot".

My QS138 is also getting hot, and I would like to compare it with other values.
(Kelly software told me that my motor goes up to ~ 80°C inside, but the controller does not get over 33°C)
My Build (Bultaco Sherpa T350 -> QS138H70) :
viewtopic.php?f=12&t=110352

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