KCR monsterebike

[kcr]

Hi everyoneSome time ago I uploaded here some drawings of ebike I wanted to do. Unfortunatly plans have changed to such an extent that a completely different vehicle has been created, so I put in a new thread which will be a big report on the production of this machine. Some of you have probably already seen the pictures on facbook, but here it will all be shown a little more so enjoy.

1. The Idea

More than 2 years ago I came up with the idea of making my own equipment (not knowing beforehand about the existence of the Ebikes). After analyzing the market and probably all possible vehicles available, I found that none of them suit me and I will make my own, different than all of them.

2. The Project

The main idea was a hub engine mounted centrally. I heard a lot of pros and cons, but that was my vision, and I decided not to give up on this idea at any cost, even though I was repeatedly spoiled by this idea.
Originally I also wanted to make some kind of mini gearbox so that it would be possible to halve the rpm on the wheel and at the same time double the torque to prevent the engine from heating up and allow for long fun in the field.
Why a gearbox and not just a second sprocket on the wheel?
Well, because I wanted to be able to change the ratio by fingerfrom the steering wheel instead of having to stop and change the sprocket manually. I made the gearboxbox, it was supposed to be the first milestone to determine if I could handle the whole ebike. I made little bit more than in plan because instead of 2 gears it became 4, the whole thing also grew and gained weight.

https://drive.google.com/open?id=1zcPTm7iq0tU5-3J3JJDLqEpwDBRa-UKf

https://drive.google.com/open?id=1PoJMNpbU74XVG8857gW7fqrv5ImuNJJL

https://drive.google.com/open?id=1bIOcUEVrpBfVUj5rVEJ6ED8IHLaWQFfF

https://drive.google.com/open?id=1up2pTknQLbJDJCadLrRAuZ-VW2t1H51c

Unfortunately, with time, the design of the ebike started to change and the gearbox started to mismatch more and more and more, so it went away. Nevertheless, I still have this solution in my head and the next project will have 2 gears (off-road and road)

Here, too, I decided to stop makind 3D models, it's high time to do something physical to have tests in the field. To confirm the sense of this idea and the sense of making a hubmid.
The frame was originally supposed to be a tube truss with a suspended package, but the workmanship exceeded my workshop capabilities, so I made "sealth bomber similar" box, which is the easiest possible solution.

https://drive.google.com/open?id=1fcEbTC-UtUMT-MIuPZkASdEhkXMwhlHI

https://drive.google.com/open?id=11CsRV-tV2i4UlKGtuQj9c2psEH1zkpNc

3. The Production

And here it started for good, most of the parts were made several times because of the surprises that appeared in the assembly, which made welding difficult or simply did not fit the style.
Eventually I gave up the pedals too. I'll only give them that they won't be chained to the engine (I don't really have idea to do that). My plan is to take a shaft angle sensor, connect with Arduino and give control of the pedal cuff. This is plan for the future, so far there are footrests

4. Equipment

- material used - bead blasted stainless steel (Aisi 304) and anodised aluminium (PA4)
- motor - for now i have there QS205 motor but there is space for QS273 too (universal frame)
- controller - sabvoton 72150 unlocked
- battery - 20s20p to 20s24p VTC5 (dont know yet)
- wheels - 19'' aluminium motorcycle rims, 3,2mm spokes, bicycle hub with holes for 2 brake discs, shinko enduro tires 2,75' width
- there will be also Arduino with some extras
- front sprocket 24 teeth, rear 40 teeth wich gives me about 50-60 km/h Vmax but huge troque. I planned to make second set of wheels with flat supermoto tires and use there 1:1 gear ratio sprocket. Changeable to situation
- chain - moto did 420H
- i'm working on motocross seat instead bike one
- shimano saint breaks
- rockshoxx suspension
- weight about 80-85 kg depends of battery size
- space for 530 pieces of 18650 batteries and controller, if you put controller outside you can put inside about 650-660 batteries.
- all parts made by CNC machines and welded by proffesional welders.
- motor and barrery in middle of bike gives good weight centre point.
- motor with swingarm on the same axis makes possibile to remove chain thightener

Photos below

https://drive.google.com/open?id=1xtnWuIZV5W3Wq4RWVq7S8PDHF-RVJ57M
https://drive.google.com/open?id=1d9xE8Th0CwQNi7IBn93kX9VAhVS2RRWt
https://drive.google.com/open?id=1ciWuH4KM6gx0vshEnrzfO09z6HiD_uRv
https://drive.google.com/open?id=16bd82iNh2IL2yPyU-7gd25tJoPLBgywx
https://drive.google.com/open?id=1TOmRpy0WKzMVcw4s21LkQhjNIBLmIkTl
https://drive.google.com/open?id=1v93u92x9PSZ7prBRMCauKhw-fyebb8uQ
https://drive.google.com/open?id=10sNYSms-iM9iqvkPKEUAhGYuLP3HKkco
https://drive.google.com/open?id=1X-s-uXw9Ty2JX6fPisSLACxM2p6hjN72
https://drive.google.com/open?id=1aU3nT4AJQxKXpjcVCKc0X6HJvJNNZzvQ
https://drive.google.com/open?id=14Jv-l2Q1555_CuGyyLma2P80mGZbaBGu
https://drive.google.com/open?id=1oAvoYrbuIXG_yXVT0_VARc6SF0NtnjoB
https://drive.google.com/open?id=1EhdWC68EpIqV9XDU_-ly7E-s7_voGVa0
https://drive.google.com/open?id=10-4fl5zrtRQWLvyQ12-_FmWVPKTr4CoR
https://drive.google.com/open?id=1nlBGJZ2sl0SpQqNcQhoweibecMDfSFt_
https://drive.google.com/open?id=1CCBAAgXV7kNYUIzEN7sgwhvmwe5h_2nt
https://drive.google.com/open?id=18uLzqfM9BRaW1SkXyx82YNisqRA-_8KO
https://drive.google.com/open?id=1n5el8pNrihfcrJS1ghMhVG5NrC8SsXQE
https://drive.google.com/open?id=12zq50hKeuZZUbKjRowhiAKj5F27Tc7f5
https://drive.google.com/open?id=1Z51FA9cuFr013hNbeFI5tkeP6lCWoCpK,
https://drive.google.com/open?id=1QBjW8Y5MKRF_l7TxQCiWZYBYu1C3enzU
https://drive.google.com/open?id=1g_HHcagDCeGPVJVU4oHITdm-FpvK7c1N
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https://drive.google.com/open?id=10lEI-oslLMJaGtOfqcUnQwjjeRyVlet1
https://drive.google.com/open?id=1v6xSQc55ua1qabeVIsjw1gI1Ngo1bqVN
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https://drive.google.com/open?id=1ouGIUxCDhnhiCUAqpEXs-fy67Xi47Vhd
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https://drive.google.com/open?id=1nse96v16mMaTs5BB_x8HW6absH6Qjbk8
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https://drive.google.com/open?id=1ilPJf29nlutlWveAMAX0LrsFCZIBr5Nf
https://drive.google.com/open?id=1ssfBFAxNlGMIPwGSUK_IN0SxXwsWcXBZ
https://drive.google.com/open?id=1JNw_D10CWpKkCF_q1stQLP9_fM4mxKs_
https://drive.google.com/open?id=1INAhMKSHGyLF9aHU81MKVCIudR_z3qAH
https://drive.google.com/open?id=1I-eN_y32xlJIom9HpevuWGa2OVjHU7Ys
https://drive.google.com/open?id=1OiaGzTO1qHYJjMZd_QEeynZwABnhLjlf
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https://drive.google.com/open?id=1Md6jjWOMn1KuQWYIl-wvgJlzCQkYOXc2
https://drive.google.com/open?id=1mS_QPVUjcWPlbLmOfo2RZxnej507rOvF
https://drive.google.com/open?id=1w3vkweHH-KBAHMw1ZkuPzJavoBRHcooK
https://drive.google.com/open?id=11RTNOKOximIXVz3nR2qTA3gd2RXPS_4x
https://drive.google.com/open?id=1zxnfYUHZXV5Lo9EF0ODgZVJYZMPZ1vZO
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https://drive.google.com/open?id=1AHAiVhco8qa7JaduhpuDni-bWcnbAYR7
https://drive.google.com/open?id=1HVxr7H17Z-Ul_C3w5eMOSHGcaQPTHRGr
https://drive.google.com/open?id=1gqfDwzjkfURJ7Kyo8kYrBAe7hF78NpBI
https://drive.google.com/open?id=19JK4HCtgHWxj28dpIEIkN0E--uJb-4JC
https://drive.google.com/open?id=1HCnQc7XA3_vPbxsj_QTiEennv-vUIyui
https://drive.google.com/open?id=1_b7QGFBfKxuLwvVHe4CFEDnyE9jZPRAW
https://drive.google.com/open?id=1jymgb8wS4KJlUchK8URwtfphfMs--1K-
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https://drive.google.com/open?id=1cL3oxsy14jGsDbFaYPK99Gq-r4tkIz3D
https://drive.google.com/open?id=16wXtlM58RS4QjxwwOsOlpmTtDYVZ_ypp
https://drive.google.com/open?id=197ZcyxAC-fO1cuA_aT4uhkz8v7XsdP4b
https://drive.google.com/open?id=1hA7LpGDUb_I8dbtlFYlF6Z5TS3akO24m
https://drive.google.com/open?id=1MrwFc8Un3KpSNwxFdWJg64rBJ9KcYYlR
https://drive.google.com/open?id=1aSdeIAnR960WWmlD4pyM9QAmH3qWrDWb
https://drive.google.com/open?id=1R5b8Im7ST1SkprM5FQhWjKQlTwAJ_8lk
https://drive.google.com/open?id=10l_KY4BcKCgTFf8O-gaYWRydvX7WX-vv
https://drive.google.com/open?id=1TLXLXFrflgw2boiHXnymafIZ1LwPrhrN
https://drive.google.com/open?id=1jLzcJYX_STbD6TYFZredP9J4Px1LHji5
https://drive.google.com/open?id=1Etx134L-HKO4EZlAkNenvDTJimiDe5oo
https://drive.google.com/open?id=1hR715mUgtEkQtfBFqqkl0eebuFo_HzVv
https://drive.google.com/open?id=1wIM8TXYSZRqbL7-7yY5Ttfs1tj-5BoXN
https://drive.google.com/open?id=1qcu3q8RcBttAOslhuodpseP39CHupW6K
https://drive.google.com/open?id=1g9WvqRGPXu6N_yDxsCzzFNeHGyEENiNN
https://drive.google.com/open?id=13al-38gnl9uOBsL00NU3k59BFvYGVx3q
https://drive.google.com/open?id=1KwFx-gKCKRqws_3eVmBOoFDUAnIaGoSl
https://drive.google.com/open?id=1JzthT0-4kipo0Ub46El6yaH7vhH8115-
https://drive.google.com/open?id=1wxCcZLuZ_P-UdmuoqJb2CupcV6GFx5gQ
https://drive.google.com/open?id=1zS9-MGCVGloJQrKlDvb-dYNDXzKZd0bT
https://drive.google.com/open?id=1TuhK25cFQIjOe3qs0YiMeDEjOdJa4g7m
https://drive.google.com/open?id=1Z5Amv_Gzv6ngYboecpL8QFGz9BZ_W7Rh
https://drive.google.com/open?id=1vd_VSPSNtRTBVRcIZo7bdCMKO0IN1i7u
https://drive.google.com/open?id=1jEwyifWR9KYUiqHvHT9erHTm0iX4ylDm
https://drive.google.com/open?id=1CnclA9g92et0S0COqGLIhOcwNwWfQVnk
https://drive.google.com/open?id=1Gsa_wiRubkRt-f9XJv77XrhdqIknFy3F
https://drive.google.com/open?id=1B1hxxSp7a-3lYYNYxd2--49GVwL4ETSS
https://drive.google.com/open?id=1Rsal7TO5M_Q7y2_Drrf88xysw5O_Ea5E
https://drive.google.com/open?id=1uR98fo6DKuw67VD_hdR3J9m-XkFdx_3j
https://drive.google.com/open?id=1OU258W5dOxOsHq3B72ccN3bqEs21r5eB
https://drive.google.com/open?id=1NPERmjQCWeLtP8Wuo6LoCUSwllCRHZIu
https://drive.google.com/open?id=1GtjLT2sJBYHhroRNPpKmN94qtNJMJmGJ
https://drive.google.com/open?id=1oxH8sXyohAYlkxkCyu-mRw27L4UYXyww
https://drive.google.com/open?id=1rrNy60oxgH6d1k6sSs3b5DZpzgWacuV1
https://drive.google.com/open?id=1JhvCqSaZko7vcXgl8tBjVu_XFFJ24Vpr
https://drive.google.com/open?id=1T0co9dkX0G0COqxHAlpF8EIGfBh0wN0d
https://drive.google.com/open?id=1rOsY6hrhQ8zrUzVaOZnakBcnBT97IUus
https://drive.google.com/open?id=1bAZlYvzzqmMlGqNsWfP0mnEdmUBWi2BC
https://drive.google.com/open?id=1svIuAeb7O4-IfOh42vDvDtSCnRO9voyI
https://drive.google.com/open?id=1oBFD-bBzNUe6-OUdyE2avoAB73o9XjqJ

Well, that's it, I hope I'll be flying in the woods on vacation while testing, for now I've filed this solution with the patent office

I'll post the reports from the end of construction and testing here.

Greetings to those persistent in scrolling - you will have sourdough on your finger from spinning the mouse wheel

 

[DanGT86]

Beautiful work! It looks really tough. Excellent color choices as well.

I am curious if you will get any side to side wobble? The vertical sheetmetal plates That join the swing arm to the main frame box look like they could use some bracing between them to prevent it from racking when viewed from the top. Then again the motor is not in the front frame so its not like they will be pulled unevenly by the chain. With the motor and swing arm sharing a pivot maybe the only forces on those plates are vertical?

Did you do stress analysis simulation with your cad design or just use the cad to get the geometry?

I'm always amazed at how people like you can do a totally from scratch design like this. Where do you even start?

 

[Dauntless]

I'm really intrigued at the sight of the motor right at the pivot for the swingarm, where some center pin should be. What are you up to there? Is this just hinged, not shafted together at all? The sprocket is on the other side, we don't even see how the motor shaft comes through.

 

[kcr]

Beautiful work! It looks really tough. Excellent color choices as well.

I am curious if you will get any side to side wobble? The vertical sheetmetal plates That join the swing arm to the main frame box look like they could use some bracing between them to prevent it from racking when viewed from the top. Then again the motor is not in the front frame so its not like they will be pulled unevenly by the chain. With the motor and swing arm sharing a pivot maybe the only forces on those plates are vertical?

Did you do stress analysis simulation with your cad design or just use the cad to get the geometry?

I'm always amazed at how people like you can do a totally from scratch design like this. Where do you even start?

I know that plates looks weak, but i think that it will be enough. Its 5mm thick and with extra foldings to avoid bending and its pressed to motor shaft by tapped bushings (where bearings for swing arm are placed). Also this is prototype, if something will goes to crack i will weld there extra stiffenters.
Regarding to stress analysis - i'm learning how to work in this software and for now i'm too small to make good analysis. Everything will be showed after few hundred kilometers offroad

I'm really intrigued at the sight of the motor right at the pivot for the swingarm, where some center pin should be. What are you up to there? Is this just hinged, not shafted together at all? The sprocket is on the other side, we don't even see how the motor shaft comes through.

motor axis = pivot for swingarm, everything is mounted on this axis.

 

[Dauntless]

But how? I can't see the shaft used structurally. Why would the two sides not flex independently?

 

[kcr]

swingarm is mounted on bearings and bearings are mounted on tapped bushings mounted on motor axle

 

[efMX Trials Electric Freeride]

of course it's possible, see zero, etc.. but how about some renders etc for public consumption.. without click to some off-site drive, location ??..

 

[Overclocker]

very nice build! excellent workmanship. but please put it up on some kind of gallery. i'd love to view all your pics but it's too slow to click one by one

btw i'm also working on a very similar build.