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  1. J

    18650 spot welding -how to- ULTIMATE REPOSITORY

    Crossposting from my build thread to ask some pack assembly advice: I am still at the point of having 20 out of 22 9p sub-packs constructed (see: https://imgur.com/a/gsK9c), I have the materials to finish the rest after ordering some replacement HG2 to replace the ones I blew up during my...
  2. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    Hey sphere! I have resurrected my build thread to ask some advice. I am still at the point of having 20 out of 22 9p sub-packs constructed (see: https://imgur.com/a/gsK9c), I have the materials to finish the rest after ordering some replacement HG2 to replace the ones I blew up during my...
  3. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    Getting close now! It's been a very painful process, but with 20 out of 22 9p packs welded, soon I will be able to start the actual pack assembly. https://imgur.com/a/gsK9c It seems that I have been getting myself in trouble for no reason by trying to weld with one electrode on the cell cases...
  4. J

    18650 spot welding -how to- ULTIMATE REPOSITORY

    How should you size this? What margin would you add to a pack circumference?
  5. J

    JP spot-welder, FET-switched, timed adj. pulse

    I agree heartily with this; freewheeling diodes can reduce the requirement to dissipate inductive energy in the leads, but not in the battery/capacitor path. Hence, you can avoid a freewheeling circuit by making a more robust snubber. In my welder, each of the six switching cells has one...
  6. J

    Adaptto Mini-E/Max-E Owner's Thread

    I did find an empty plastic bag (and a machined disc brake spacer) in my QS box, hmm!
  7. J

    QSMOTOR,0.5-12kW Electric Hub Motor & Mid Drive Motor Manufacture China

    Hi Vito (and lurkers), I have a Mini-E and a QS205. The pinout of the QS hall connectors appears to be (looking at the pins of the motor side) ((+,T,-),(H1,H2,H3)). There are two redundant sets of sensors and connectors, and one supplied female connector. It had some goop installed over the...
  8. J

    Adaptto Mini-E/Max-E Owner's Thread

    I have a Mini-E and a QS205. The pinout of the QS hall connectors appears to be (looking at the pins of the motor side) ((+,T,-),(H1,H2,H3)). There are two redundant sets of sensors and connectors, and one supplied female connector. It had some goop installed over the end that the wires come...
  9. J

    18650 spot welding -how to- ULTIMATE REPOSITORY

    I am currently building a pack without the use of insulators. I will be gluing and separating with kapton tape etc. to kep it rigid and avoid rubbing, but I am also interested in methods like conformal coating and even conformal coat + silicone potting to aid waterproofing and thermal...
  10. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    Even with the Nyloc nuts? I'll be giving everything a tighten after the shakedown cruise. Maybe some threadlocker?
  11. J

    Qulbix Q76R Frame Kits & Complete Bikes PRE-ORDER

    Built up my Q76R frame today: https://imgur.com/a/bMGZ4 https://endless-sphere.com/forums/viewtopic.php?f=3&t=79669&p=1183257#p1183257
  12. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    https://imgur.com/a/bMGZ4 Bolted up the frame this weekend. Sticky business, molybdenum grease on every bolt and moving surface, but that should keep the bits happy. That QS motor has some serious cogging torque. The axle took two spacers on the drive side, which left the wheel nicely centred...
  13. J

    Qulbix Q76R Frame Kits & Complete Bikes PRE-ORDER

    Can anyone share photos or installation details of the Qulbix-supplied headset installation (for a triple-crown fork)? It came with cups pre-installed, but I have no clue in what order the bits go. There is a black ring, a silver notched ring, the gimbal cover thing, and the top nut. I think...
  14. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    Is the 8V for the lights pretty standard? I wonder what they think of the generic Cree T6 based lights, like http://www.ebay.com/itm/SolarStorm-12000LM-Bike-3-x-CREE-XM-L-T6-LED-Bicycle-Lamp-Outdoor-Headlight-Kit-/182047501951?hash=item2a62e06e7f:g:MEQAAOSwZ8ZW3nGO It seems that if you're...
  15. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    Suitable DC-DC converters may not be as scarce as you think, as many AC-DC SMPS will be able to be run off a suitable DC voltage, as the front end is normally just a rectifier. If it has an active PFC front end that tries to do something fancy it might not like it, but it's worth trying if you...
  16. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    Does anybody have any suggestions for headlights/taillight? I was thinking that the ideal might be something with built-in single-stage conversion/LED driving that can accept up to 90/100V, preferably with a built-in switch, though I can imagine that would be pricey. The next best alternative...
  17. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    Yeah, I can see why batteries are a lot easier to work with. A much bigger capacitor bank would also help. At least that I could do with the present hardware. My currents must be pretty high, because the on time is only 2x 200us pulses followed by a 4ms pulse. And all through only 4 FETs!
  18. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    Yeah, those CN linko connectors have the same profile and screw hole size as the Neutrik (according to datasheet, have not actually tried to put one on yet). Being 4-pin plugs, they will be great for an onboard charge coil, using two pins to complete the connection to the phase wire. The donor...
  19. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    The attached file is what led me to think that 22s9p would be easily achieved, by hacking up your Q76R frame pics with 280 cells. 198 cells is trivial by comparison. https://imgur.com/2UztfMg With your level of packing and spacing, there is some decent margin to the frame. Even if loose...
  20. J

    18650 spot welding -how to- ULTIMATE REPOSITORY

    If you are interested I have posted some details about my own homebrew CD-type welder, designed for very high power levels: https://endless-sphere.com/forums/viewtopic.php?f=3&t=79669 It's a bit more complicated than the JP battery based type, but I have worked out the major problems now and...
  21. J

    Planning/build thread, DH frame, Mini-E, QS 205 w/ LG HG2

    Thread necromancy, I have started a new build thread here: https://endless-sphere.com/forums/viewtopic.php?f=3&t=79669 A lot of the stuff in this thread is no longer relevant as I have a Q76R frame. More juicy spot welder details also.
  22. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    I have finally begun pack construction in earnest. Offroader's Q76R pack pictures gave me some solid starting points on how to best achieve a moderately sized (198 cell) Q76R pack, and so I eventually determined that a hexagonally packed layout of 22 flat 9P strips would fit straight in, giving...
  23. J

    New build thread, Q76R + QS 205 + HG2 + Mini-E

    Some of you might have seen my previous build thread here, https://endless-sphere.com/forums/viewtopic.php?f=3&t=73499 The build has evolved a bit since I first started planning it, mostly due to deciding to get one of those beautiful Q76R moto frames in place of a custom battery box for a...
  24. J

    JP spot-welder, FET-switched, timed adj. pulse

    I would be interested to know how quickly these welders switch. My own one, which is designed with RCD snubbers (interleaved on the bus between switching FETs) instead of flyback diodes, deliberately has a very slow turnoff (4us, still safely within the device SOA), with 800 Ohm gate resistors...
  25. J

    JP spot-welder, FET-switched, timed adj. pulse

    For what it's worth, if all your interconnections really are balanced then there won't be any problems changing which cells are connected on each side. I would also think about making connections with smaller wire between all of the pairs, just to let you use a BMS. There shouldn't ever be any...
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