4x4 Transport Kart from scratch

[hasp]

We already built a little 80x200cm transport cart for film work, this is it:



it was a first proof of concept prototype built out of cheap parts lying around and a lot of machining and fabrication to make it all fit, like forklift motor, lawnmower gearbox, quad axles, etc ..
build thread for that can be found here: viewtopic.php?f=34&t=104174&p=1521241


Now for the next one we decided to keep the general layout/design but switch from a handmade tube space frame to a computer designed and cnc cut unibody chassis and also switch to qs hubmotors.

this is the final design:





the lasercut steel will arrive beginning of january, in the meantime we built a interchangeable 100Ah 48v LifePo4 Batterypack using flightcase hardware:





..and we did the first bit of metalwork, the thingys that hold the 4 qs hubmotors:

[Vbruun]

Do you intend to sell them?

[spinningmagnets]

Consider adding an inverter that is designed to run off of 48V DC and convert it to 120V AC, then add common outlets on the front and rear for unexpected issues. Of course add breakers, etc

[hasp]

Do you intend to sell them?

depends on how well Version 2 turns out to work and also depends on wether assembly goes as seemless and enjoyable as we dream it will

[hasp]

Consider adding an inverter that is designed to run off of 48V DC and convert it to 120V AC, then add common outlets on the front and rear for unexpected issues. Of course add breakers, etc

Nice Idea, actually we might. (except for going for 240V, because europe)

Also thinking about a 12 and 48dc outlet, as many moder Film Lights run those Voltages

[hasp]

CNC lasercut steel has finally arrived !

[spinningmagnets]

Nice! I didn't see, whats the voltage of the battery pack?

Also, what country is this in?

Thanks for posting this project here!

[hasp]

The Batterypack is a 16s 48V 100Ah Lifepo4 unit with a 320A ANT BMS.

actually we are a bit puzzled with the BMS, so if someone is familiar with it,
here is the thread:
viewtopic.php?f=14&t=114581


oh, and we are from austria

[hasp]

last welding day was only a frew hours,
heres the result of day 2:

https://imgur.com/gallery/oOKVpVW

[nicobie]

It's looking really good! Nice shop too.

[louis raaijmakers]

very cool project!

but where will it be used for? just curious.

greetings louis

[hasp]

thanks guys!

it will be used to transport lighting equipment on film sets, and as a camera platform for moving shots.

here are two of that done by our older 2wd forklift engined non-fusion designed first prototype:

transport:
https://www.instagram.com/p/B4ehcWvg0pl/

camera platform:
https://www.instagram.com/p/CO5Sl5rlUMH/

...and the reason it is that narrow is so that it fits within existing transport infrastructure, meaning a truck with shelves on both sides:
https://www.instagram.com/p/B339pYRgxPT/

[louis raaijmakers]

thanks for the reply!

cool shots damn! oke now i know why it needs to fit in a truck.

i will folow the build

[hasp]

Some more progress:

[hasp]

Some more progress has happened..


body is back from powdercoating:




did the last bits of welding using CAD (cardboard aided design (pun courtesy of badobsessionmotorsports)):





put some thick chassispaint on underbody and wheelarches:



mounted the springs for the last time:



inserted 200 rivet nuts:



cut 3mm pom scratchguard:



...and screwed it on:





motorcontrollers in place:



switches and (custom) indicators fitted:



and added quite a few extra kW with red paint:

[hasp]

were done!



here is a first testdrive with not yet limited motorcontrollers:
https://www.instagram.com/tv/Ccpz3HQKCq ... _copy_link

here are the grip colleagues transporting their dolly:
https://www.instagram.com/tv/CdIUtxeIAz ... _copy_link

first use as camera platform:

[fechter]

Excellent work! Thanks for sharing it here.

I don't think I've ever seen hub motors like those. Are those geared? Most of them are made to go too fast.

[amberwolf]

Probably this one, or similar
https://www.qsmotor.com/car-motor/
https://www.qsmotor.com/product/4000w-260-car-motor/
Kind of what I considered turning my old MXUS3K motors into for the trike in one thread around here somewhere, except the inboard mounting stuff would've been much heftier and not just an axle like that.

4000W-260-Car-Motor-01[1].jpg (25.02 KiB) Viewed 215 times

4000W-260-Car-Motor-02[1].jpg (22.94 KiB) Viewed 214 times

Excellent work! Thanks for sharing it here.

I don't think I've ever seen hub motors like those. Are those geared? Most of them are made to go too fast.

4000W 260 Car Motor
Ideal solution for your light electric car
Advantage of 4000W 260 Car Motor
1) High Power: 4000W (continuous) and max. up to 8000W.
2) High Efficiency: max. 85% to 91%. Save your battery power and energy.
3) Run more distance per charge, long battery life.
4) Support voltage from DC 48V to 96V. Recommend voltage 72V.
5) Low temperature rise, low failure rate.
6) Resistant to high current, shock resistance.
7) Actual rated power (continuous), no cheating in power.
2 sets of Hall Sensor, 1 for use and 1 for backup.
9) Customize PCB size and rim mount screws (4pcs or 5pcs).

Specification
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4000W 260 Car Motor
1) Motor Type: DC Brushless Motor
2) Version: V1
3) Power (Continuous Power): 4000W.
4) Max. Power: 6400W (peak 8000W)
5) Voltage Range: 72V (option 72V-96V).
6) Magnet Height: 45mm (second generation, powerful type)
7) Recommendation Rim/Hub: 14 inch or above
Rim Mount Screw: 4 mount screws (option 5 mount screws)
9) PCB Size: 4 x 100mm (or customize)
10) Speed: 30 – 85km/h
11) Torque: 30 – 181N.m
12) Brake: disc brake (220mm)
13) Hall Sensor: 2 sets (1 for use and 1 for backup)
14) Max. Working Termperature: 70 ℃ (peak 120℃ in 5 – 10 second)
15) Waterproof Grade: IP54
16) Color: Black
17) Net Weight: 18.00kgs
18) Unit Packing Size: 34x34x33cm/carton

Advice on Motor Speed
1) The max. speed of 4000W 260 car motor ranges from 60km/h to 85km/h.
2) The recommend max. speed is 85km/h at battery voltage 72V.
3) The speed of motor will go up when the voltage of battery increases.
4) It is better to advise the voltage of your battery and your expected speed. And we can recommend the correct motor versions to you.
5) This 4000W 260 car motor fit 14 inch rim or above, 4pcs or 5pcs rim mount screws.
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Advice on Motor Controller
1) You should choose 100-150A (power current limited) controller for this 4000W 205 Car Motor.
2) This 4000W 205 car motor can support both Trapezoidal Type and Sinusoidal Type controllers.
3) The recommended controllers are VOTOL Controller EM-100, EM-150, LB Controller 72252, Sabvoton Controller 72100, 72150 and other brands.
4) Please feel free to contact us if you have no idea of how to choose the matching controller. We will behind you all the way.

[hasp]

Excellent work! Thanks for sharing it here.

I don't think I've ever seen hub motors like those. Are those geared? Most of them are made to go too fast.

thanks! the Motors we used are the QS 205 V3, 1500w

http://www.cnqsmotor.com/en/article_rea ... H/732.html

they are not geared, but as we have 4 of them torque seems to be more than adequate for our needs.