zombiess
10 MW
Tonight was the first night I got ride my bicycle after having a ton of mods done such as switching to a 26" fork for more rake, having my rear swing arm lengthened by 8 inches, had a friend who is studying to become a mechanical engineer help me securely mount my new battery bag which can carry 30S3P
very nicely to the center of the frame.
This is what the bicycle looks like as of 11-22-11. Wheel base is 45" without me on it and it's quite comfy and stable to ride. Shock is a Cane Creek Cloud 9 and is very nice. I can run any size wheels from 20" to 26".
Motor is a 9C 2806 in a 20" wheel, 12 AWG phase wire upgrade.
Max recorded speed @ 100% throttle was 52mph, managed 56 mph at 105% throttle but the current didn't really like to drop off much below 50A once at top speed at 105% where as at 100% throttle it would drop down to 40A, pretty big difference. Not sure the extra 4mph are really worth the extra 10A of current draw.
Settings on the controller were 100% throttle, 47 battery amps (really 60A due to soldered shunt), 125 phase amps, 0.1S block time, peak off load voltage was 124.4V and would see up to a 4V sag under load, probably because it's was a bit cold. Battery config is 30S2P Hobby King 6S 20C Lipo. Testing method was several high speed runs, then several dead stop and instantly going WOT (could get a tiny power wheelie for a few feet on the 100% setting), 8" longer swing arm combined with 140mm cane creek cloud 9 air shock is bad ass.
So onto the data.
This is how my sensors are mounted in the controller
Inside ambient temp sensor which is near the 3 shunts, but not directly over them
FET temp sensor. It's not directly on the tab as I would like but it's between the cases of the two FETs and has thermal paste in contact with them. It's mounted on the green phase wire bank, not sure if this bank suffers switching losses or just resistive (if it has switching losses the temp should be hotter on this bank)
Outside temp, 12.5C
Highest logged ambient case temp was 34C and it averaged 29.5C while riding the entire time
FET Temp max was 42.7C for 1 second (3 seconds later it was down to 39C and dropping fast) and I only have a few points where the temp would get over 40C.
Average temps on the ride was 25.5C for the FET and 29.5C for the ambient case temp. This was a 10 min ride (just over 600 data points at 1 sec intervals), logging started after I had already been playing around with 105% throttle to get everything up to working temp, then switched to 100% throttle for the test.
While the controller was in current limiting mode the current draw held steady at 60A (shunt has been calibrated). Peak amp draw was 73A. Cycle analyst reported 79Wh/mile I wasn't being very easy on it for those 10 mins.
I did a quick check of the winding temps when I pulled back into the garage and got a max of 104C which proceeded to drop down to 90C within about 3 mins so it was probably about 110C before I got the probe into the coils.
The bike is an absolute blast to ride, but needs less voltage sag. 4V seems like a lot of sag, but during the day when it's warmer I don't get quite as much sag usually 2.5-3V, I'll keep an eye on it.
This controller was modded by myself following markcycle earlier post. Each 3 FET bank has it's own buss bar made from 10 AWG stranded wire connecting the three tabs of each bank in parallel to the B+ as well as each phase bank connected by tab in parallel to the phase wires.
See this post for details on the mods done http://endless-sphere.com/forums/viewtopic.php?f=2&t=33847
Observations, I don't think I'm really stressing this controller after making these mods and could go up on the current quite a bit, but I don't see any need to as the bicycle accelerates quite fast and is tons of fun. As soon as my Greyborg Hub Monster is laced into it's 20" wheel, it's getting tested next. Wish it had a faster winding than 9.5 KV, but at least it's going to be easier on my 18 FET 4115 controller.
Things to try, buy a Lyen 18FET 150V controller like the one I have, mount temp probes an see how much my mods have helped (probably quite a bit). Run the current setup in hotter weather to see what happens to the FET temps. Seems like right now they peak 30c over ambient and run about 17C over ambient average during high speed abuse. Get cars to drag race from stop lights
Hope you guys like this data.
very nicely to the center of the frame.
This is what the bicycle looks like as of 11-22-11. Wheel base is 45" without me on it and it's quite comfy and stable to ride. Shock is a Cane Creek Cloud 9 and is very nice. I can run any size wheels from 20" to 26".
Motor is a 9C 2806 in a 20" wheel, 12 AWG phase wire upgrade.
Max recorded speed @ 100% throttle was 52mph, managed 56 mph at 105% throttle but the current didn't really like to drop off much below 50A once at top speed at 105% where as at 100% throttle it would drop down to 40A, pretty big difference. Not sure the extra 4mph are really worth the extra 10A of current draw.
Settings on the controller were 100% throttle, 47 battery amps (really 60A due to soldered shunt), 125 phase amps, 0.1S block time, peak off load voltage was 124.4V and would see up to a 4V sag under load, probably because it's was a bit cold. Battery config is 30S2P Hobby King 6S 20C Lipo. Testing method was several high speed runs, then several dead stop and instantly going WOT (could get a tiny power wheelie for a few feet on the 100% setting), 8" longer swing arm combined with 140mm cane creek cloud 9 air shock is bad ass.
So onto the data.
This is how my sensors are mounted in the controller
Inside ambient temp sensor which is near the 3 shunts, but not directly over them
FET temp sensor. It's not directly on the tab as I would like but it's between the cases of the two FETs and has thermal paste in contact with them. It's mounted on the green phase wire bank, not sure if this bank suffers switching losses or just resistive (if it has switching losses the temp should be hotter on this bank)
Outside temp, 12.5C
Highest logged ambient case temp was 34C and it averaged 29.5C while riding the entire time
FET Temp max was 42.7C for 1 second (3 seconds later it was down to 39C and dropping fast) and I only have a few points where the temp would get over 40C.
Average temps on the ride was 25.5C for the FET and 29.5C for the ambient case temp. This was a 10 min ride (just over 600 data points at 1 sec intervals), logging started after I had already been playing around with 105% throttle to get everything up to working temp, then switched to 100% throttle for the test.
While the controller was in current limiting mode the current draw held steady at 60A (shunt has been calibrated). Peak amp draw was 73A. Cycle analyst reported 79Wh/mile I wasn't being very easy on it for those 10 mins.
I did a quick check of the winding temps when I pulled back into the garage and got a max of 104C which proceeded to drop down to 90C within about 3 mins so it was probably about 110C before I got the probe into the coils.
The bike is an absolute blast to ride, but needs less voltage sag. 4V seems like a lot of sag, but during the day when it's warmer I don't get quite as much sag usually 2.5-3V, I'll keep an eye on it.
This controller was modded by myself following markcycle earlier post. Each 3 FET bank has it's own buss bar made from 10 AWG stranded wire connecting the three tabs of each bank in parallel to the B+ as well as each phase bank connected by tab in parallel to the phase wires.
See this post for details on the mods done http://endless-sphere.com/forums/viewtopic.php?f=2&t=33847
Observations, I don't think I'm really stressing this controller after making these mods and could go up on the current quite a bit, but I don't see any need to as the bicycle accelerates quite fast and is tons of fun. As soon as my Greyborg Hub Monster is laced into it's 20" wheel, it's getting tested next. Wish it had a faster winding than 9.5 KV, but at least it's going to be easier on my 18 FET 4115 controller.
Things to try, buy a Lyen 18FET 150V controller like the one I have, mount temp probes an see how much my mods have helped (probably quite a bit). Run the current setup in hotter weather to see what happens to the FET temps. Seems like right now they peak 30c over ambient and run about 17C over ambient average during high speed abuse. Get cars to drag race from stop lights
Hope you guys like this data.