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  1. cozy35

    Li-Ion UPS

    Folks, I need some help/pointers. I need to make a UPS for a load of 8.4V at max 8A. So I am figuring I could use a 2S3P 18650 setup to supply the 8A demand at 8.4V being held at optimum voltage from a AC to DC PSU of 10A and a buck converter for the constant 8.4VDC connected to the BMS. The...
  2. cozy35

    New Approach to 4500W Mid Drive

    The problem is that chain-wheels come in different tooth numbers and one chain link can really mess with chain slop. The BB brace is to adjustable to take up any excess slop.
  3. cozy35

    New Approach to 4500W Mid Drive

    Indeed a 3d printed temporary part. It is a fitment test for a carbon fiber cover to enclose the bolts and ring-gear. Basically just to tidy up the box assembly.
  4. cozy35

    New Approach to 4500W Mid Drive

    Since the motor will mount directly to the input side of the box which is also aluminum it should act as additional heat sinking material. I am planning a centrifugal fan to draw cooling air through the stators and this should also aid in cooling.
  5. cozy35

    New Approach to 4500W Mid Drive

    The latest parts and temporary assembly of the gearbox. The assembled Box weighs 1178 grams and the APS 8055 motor adds another 1100 grams.
  6. cozy35

    New Approach to 4500W Mid Drive

    The latest rendering so long.
  7. cozy35

    New Approach to 4500W Mid Drive

    OK, so I am waiting for admin to reset my password and change user e-mail. Somehow I cannot login from my phone to post pics. I will be out of town until Saturday. Taking a road trip to Hakskeen Pan where the current tests are underway of the Bloodhound for next years land speed record. This is...
  8. cozy35

    New Approach to 4500W Mid Drive

    Yes, after quite a long busy work schedule. I have just last week received the cnc machined parts and also the VESC 100A controller. I have now been waiting 6 weeks for the APS8055 Motors. It is taking so long because of the reworked shaft to suit my needs. Once I get the Motors in hand I can...
  9. cozy35

    Vedder VESC

    Is anyone using or have experience with the Vedder ESC as supplied by MayTech in a sealed aluminum case? I ask because I would like to know how sealed it is and will it be okay in wet muddy weather in and e-bike. They claim it is sealed, but I just received mine and it appears not to be fully...
  10. cozy35

    New Approach to 4500W Mid Drive

    I have been very busy lately with increased business demands and I also purchased and assembled my own 3D printer to alleviate my dependency on others for concept pre-cnc parts. My printer is up and running and the first test print proved comparable with many other commercially available...
  11. cozy35

    New Approach to 4500W Mid Drive

    That would work, but since I am using off the shelf gear sets and is not available.
  12. cozy35

    New Approach to 4500W Mid Drive

    Ha ha ha..., hence the version V1.0 inclusion. I should have said V1.0 done for now.! It never ends.
  13. cozy35

    New Approach to 4500W Mid Drive

    I think I am done now with the version 1.0 of the 4500W Mid Drive System. Specifications: 4500W Alien Power Systems APS 8050 Out Runner (50KV) Two Stage Planetary Reduction Drive. - Stage one is 4:1 - Stage two is 3:1 (Optional can be 4:1) for a 16: reduction - Total of 12:1 on the output...
  14. cozy35

    New Approach to 4500W Mid Drive

    Tomorrow the laser and water jet cutting order will be placed. I am sure I am close to the stage of conclusion of the initial version 1.0 design. (not that it ever ends) The mount design are done and I will post some pics later. The real challenge now is to make these universal for all the...
  15. cozy35

    New Approach to 4500W Mid Drive

    I read up some more about the HMPE webbing and I stand corrected that this is Polypropylene? I was incorrectly under the impression that Polyester webbing is superior to Polypropylene. Googling HMPE did not really produce any results, unlike "Dyneema"! I actually have loads of this stuff in 1"...
  16. cozy35

    New Approach to 4500W Mid Drive

    I have also considered Kevlar Webbing. Just not sure how it would stitch up. One would have to sort of seal the ends to prevent fraying. https://www.osnf.com/kevlar-webbing
  17. cozy35

    New Approach to 4500W Mid Drive

    Polyester Webbing is stronger than Polypropylene ad Nylon, and it also is great at repelling water. I have incorporated my own T-Bolt design and the strapping rides on the frame and as I stated a 0.5MM poly-carbonate clear sheet can be used. Poly-carbonate is tough stuff. For that matter many...
  18. cozy35

    New Approach to 4500W Mid Drive

    Here is the in-frame mount setup. Using the same Webbing strap system or T-Bolt setup. This method of mounting does not require BB bracket mounting, simplifying installation. It simply wedges between the seat stay and the down tube. Now, in order to make the Planetary Box End Plates...
  19. cozy35

    New Approach to 4500W Mid Drive

    Yep, that is what I will use on carbon frames.
  20. cozy35

    New Approach to 4500W Mid Drive

    So, the hint for the T-Bolt solution inspired me to come up with this neat mounting style. It is low profile, functional easy to make. A simple flat laser cut band with slotted ends and bent to shape.
  21. cozy35

    New Approach to 4500W Mid Drive

    Thanks for the tip. I never even thought about that. A good backup material would be clear Poly Carbonate Sheet - this then for metal framed bikes. When it comes to carbon, I still believe the Polyester Webbing style would be better.
  22. cozy35

    New Approach to 4500W Mid Drive

    Here is the assembled example as mounted to the down tube. Not showing the BB at this stage.
  23. cozy35

    New Approach to 4500W Mid Drive

    I have been toying with an effective mount that will not destroy carbon frames. For that I steered away from conventional U-Bolts and metal clamps. Carbon frames do not take kindly to these methods. I decided to use Polyester Webbing Belt material for this. It will also protect paint finishing...
  24. cozy35

    New Approach to 4500W Mid Drive

    The BB mounting plates and a remodeled Box End Plates are done, and now for the saddle to down tube mount. I think I will have to make a spreadsheet to determine the various required spacers to cater for the different BB spindle sizes. The saddle mount should be a universal fit for down tubes...
  25. cozy35

    New Approach to 4500W Mid Drive

    I don't believe that this setup would ever exceed 3000 Watts. The motor I am using is rated 4500 Watts and has 9.2NM torque and can handle up to (14S @ 4.2V/Cell) 58.8 Volts @ 80 Amps. I plan on maximum of 50.4 volts @ 50 Amps. So my maximum power use will not exceed 2400 Watts. Calculations...
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