Norco E-Line (Adaptto MAX-E + MXUS 5K)

GrayK

1 mW
Joined
Jan 4, 2018
Messages
18
Hi guys!

I decide to convert a Norco A-Line into an electric bike.

The plan is to use an MXUS 5K Hub motor and Adaptto Max-E controller with a 20s 10ah zippy compact lipo pack. I'm going to use either a C2000 or Teensy 4.1 for thermal management (trigger fans from thermistor setpoints) and CAN control of the Eltek 3.3kw OBC. I hope to integrate a J1772 inlet in it to help compensate for only 10ah of capacity. Since I am going to actively cool the battery I figured running C rates in access of 2 should be relatively safe enabling "quick charging". The cooling setup works surprisingly well since the Delta fans generate an absurd amount of static pressure.

Here are some photos attached
 

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Here is a bit more progress on the bike. Working away on the battery and charger system. Just ordered some CANbed boards in the mail since they are tiny and cheap ($20 a pop on mouser with a SAM32 based mcu!)
 

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Just finished the bike today and took the first test ride around. Charging is working great. I programmed a spare C2000 launchpad as a CAN controller because I had one on hand and its works great. Next up is to figure out the J1772 handshake and I'm ready to roll. For now, I will just use the outlet. The charger can do up to 25a so it's possible to charge the battery in a little less than 30 mins on J1772!

I went up to speeds of 62.5mph and didn't even max out the throttle maybe 90% of the way there. super scary and I was shaking after the ride.

I will do a detailed range test tomorrow but I think it's heavily dependent on how hard I'm riding on it.

This isn't the best-looking build and I will probably rewire/clean it down the road but for now, it's good enough and I'm going to save that for another day.
 

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I just finished the bike up!


I'm having some issues with the Adaptto BMS since there are some I2C errors between master and slave BMS modules. I think something is wrong with one of the TI 4s BMS ICs but I haven't given it a good look yet.

I want to design a better BMS down the road and was looking into the NXP MC33771B ASIC. Pretty cool little chip with a built-in resistor bleeding network. The only issue about going on this path is the Adaptto BMS uses I2c between the BMS and controller so if I wanted to use the original display I would need to use a logic analyzer to figure out how the voltages are a bit packed to recreate the same signals with a new IC.
 

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