"Chain Puller" mid drive from industrial BLDC motor

BalorNG

10 kW
Joined
Nov 10, 2019
Messages
516
The HPV to be 'electified' is a DIY velomobile intended for long distance travel.
I want a relatively low-power (about 150watts) efficient mid-drive that will integrate into transmission exactly like e-assist of Tetz:
http://www.recumbents.com/mars/tetz/E-Assist.htm

I've bought this motor spindle with integrated 10:1 gearbox:
https://www.aliexpress.com/item/32797544178.html

Paired with 13T cog on the spindle and 50T chainwheel it will pull my legs with around 100 RPM - my preferred cadence (because short cranks). I like this not just due to weight, but because it seems to emulate a fixed gear bike that actively helps you pull though dead spots, optimizing biomechanics and w/o hassle of ACTUAL fixed gear bike (like having no gears and having to pedal ALL the time, even steep downhill).

It will be combined with a hefty 24v (7s) battery.

I'll be needing an inobtrusive setup with thumb throttle and, most importantly cruise function - cause I'll likely be using it for hours and hundreds of miles (conservative CFD estimates of my shell suggests about 50 kmh on a combined 300 watts).

What kind of controller should I use? Using ESC like on Tetz trike w/o a current limiter is tricky, plus I like ability to use e-bike brake handles to stop assist in an instant.
As I understand, KT controllers with LCD should work - but would they, given 'unorthodox' nature of my drive? For instance, it will likely give out wildly incorrect speed due to two step reduction, and PAS is obviously out of the question.
 
I have been thinking about doing something similar. Sorry I don't have any answers for you at this time.
I have a fairly extensive collection of industrial motors. I hadn't thought about using a gearbox with them, that's a good idea. Too bad motors like that don't usually come with a right angle gearbox, that would make the fit a lot better. I suppose on a 'bent, it shouldn't be too hard to put the motor somewhere that it doesn't interfere with the rider's feet. I'll have to rummage through my parts collection to see if I have any right angle gearboxes.

I'm hoping I can use an industrial drive with mine and avoid the ebike controllers. I have a few controllers that would be perfectly happy with 48v. A microcontroller should be able to incorporate a torque sensing bottom bracket as well as a throttle.
 
Yup, on an RWD bent (and especially velo) you have quite a bit of freedom with transmission, though there are still limits.
Admittedly, for maximum efficiency you'd want a chain reduction and a smaller KV motor, but I thought that a difference of about 2% does not warrant going with a system that is likely much noisier and much more obvious... though it remains to be seen how much noise the gearbox is going to make in practice. Also, unlike RC motors industrial BLDC is designed to work w/o forced cooling and in contaminated environment.

I've got idea from Tetz 'low power e-assist':
http://www.recumbents.com/mars/tetz/E-Assist.htm

I'll do some tests with a power meter and watt meter to establish real efficiency.
 
Ok, please don't repeat my mistake - this motor is an absolute shite.
Here are tech docs of similar motors, I wish I've found them earlier:

http://gemsmotor.com/nema-23-round-brushless-dc-motor

A motor similar to mine has about PEAK 65% efficiency - which is pretty much what am I getting. WTF those motors are so expensive , heavy AND inefficient?!
Fortunately, I suspected something like that and have a couple of copter motors incoming, those babies are TONS more efficient and 'torque dense'.
https://www.dji.com/ru/e2000/info
I'll have to make an axle adapter to use gearbox with it, though.
 
Back
Top