Trilska
10 W
Hello endless-sphere
This is the introduction for my upcoming summer project. A project I party take on as a reward for myself since my studies are finally going decently (studying electrical engineering, and in writing moment no exams behind me). Another factor is that I have not been able to find job for the summer break. So I have a huge amount of time to kill and some saved up money from my time in the military. So after mostly lurking around on the forum for two years I am finally ready to start.
My platform, a Kmx Typhoon I bought new, I have put around 2000km on unassisted over the last year, and I must say I do not exactly regret the desiction to purchase it, and I secretly planned to electrify it from the start.
So here is the target for the project.
Range: 50km at 40km/h
Speed: Quick to 50km/h so geared for around 55km/h on nominal battery voltage
Overall build quality: I plan to use this project as a demonstrator of what I am capable of, both in the terms of my on-going education and what lies outside it.
Weight: Not critical but I would like the electric drivesystem to be under 20 kg.
Sound: Dead quiet,
Components most of it yet to be ordered, feel free to ask or give your point of view to the components or the system in questions
Bike KMX Typhoon
Wheels: 305 (16'') front 406 (20'') read. Using the stock big apple tires (quite worn after a year and 2000km unassisted, planing to replace with hookworms)
Breakes: Stock works ok but require a lot of service to maintain balance between the tires. Planing to replace.
Motor: A two speed hubmotor suplied by John in CR http://endless-sphere.com/forums/viewtopic.php?f=31&t=40859
To use in a midrive configuration. The motor is just big enough to fit between the seat and rear wheel.
Controler: Jet to be decided, hopfully the compatible sinwave controler that John in CR are working on. 100V components around 50-60A
Gearing:
I plan to utilize a belt drive based on 8mm HTD to gear down the motor 2.1:1 (38t front, 80t rear). I will CNC the pullies myselfe. A 20mm wide belt will have just enough clearance between the tire and frame. Last i plan to utilize the two speed gearing to shift the efficiency band to a lower speed for steep hills and or heavy loads, the low speed will also enable the use on normal roads with power limited via a CAv3. Shifting betwene the two speeds will in the end be handled via a microcontroler and a servo, with the shift point depending on speed and if max thrust is required (more than half throttle) och efficiency (under half throttle).
I wish the system to freewheel so a White industries eno will be mounted in the front pulley.
Battery:
24s lipo. (Before you say anything, i know it is on the edge for the 4110fets etc, but it should probably be ok with a high inductance motor, 240uH in high, And if it breaks i will have to learn how to fix it. )
89V nominal utilizing 6s turnigy 20C bricks. either 10 or 15 AH to be desised with a total capacity of 890wh or 1335wh.
BMS: Founding power programmable BMS with throttle intercept (LY.CS-bms).
http://endless-sphere.com/forums/viewtopic.php?f=14&t=40774
Probbebly a little to high energy consumption in passive mode, but enables the use of a monitoring display with temperature probe. A good idea for the control freak.
Breaks: Hygia multi, quite pricy but made for trikes and able to get with e-break and parking break. With a such heavy and powerful system i do not want to be a cheapskate on the brakes. Especialy when only having front brakes and no regen.
Rotors: Might be a little to much overkill with 2*203 floating rotors but with no real penalty in the terms of weight and price, so why not?
On the cheaper side for 203 floating but they have good user feedback, except being a little heavy.
CA: Picked up a V3 during the X-mas sale. Plan to use the tourqethrottle and temp limiting/monitoring. Will probably need to flash if with the latest firmware.
Battery compartment The plan is to print two "boxes" containing 6 (6 bricks fit comfortably inside printing volume) bricks each with the 3D printer i have access to (RapMan3). Shape and placement is yet to be decided.
Charger
Bought a used kingpan 1.2KW charger here on ES. Works but needs to be connected to an unused phase otherwise it trips the curuitbreaker.
This is the introduction for my upcoming summer project. A project I party take on as a reward for myself since my studies are finally going decently (studying electrical engineering, and in writing moment no exams behind me). Another factor is that I have not been able to find job for the summer break. So I have a huge amount of time to kill and some saved up money from my time in the military. So after mostly lurking around on the forum for two years I am finally ready to start.
My platform, a Kmx Typhoon I bought new, I have put around 2000km on unassisted over the last year, and I must say I do not exactly regret the desiction to purchase it, and I secretly planned to electrify it from the start.
So here is the target for the project.
Range: 50km at 40km/h
Speed: Quick to 50km/h so geared for around 55km/h on nominal battery voltage
Overall build quality: I plan to use this project as a demonstrator of what I am capable of, both in the terms of my on-going education and what lies outside it.
Weight: Not critical but I would like the electric drivesystem to be under 20 kg.
Sound: Dead quiet,
Components most of it yet to be ordered, feel free to ask or give your point of view to the components or the system in questions
Bike KMX Typhoon
Wheels: 305 (16'') front 406 (20'') read. Using the stock big apple tires (quite worn after a year and 2000km unassisted, planing to replace with hookworms)
Breakes: Stock works ok but require a lot of service to maintain balance between the tires. Planing to replace.
Motor: A two speed hubmotor suplied by John in CR http://endless-sphere.com/forums/viewtopic.php?f=31&t=40859
To use in a midrive configuration. The motor is just big enough to fit between the seat and rear wheel.
Vital stats:
Rated power- 2500W at 72V
Kv- 17rpm/v in high 9rpm/v in low
No load current at 75V- 0.9A in high 0.35A in low
Hall sensor angle- 120°
OD of motor shell- 173mm (6.8") exluding rim flange
Stator diameter= 150mm (5.9")
Stator width (motor length)- 50mm (2")
Weight- under 10kg (about 8.5kg trimmed down for mid-drive use)
John in CR
Controler: Jet to be decided, hopfully the compatible sinwave controler that John in CR are working on. 100V components around 50-60A
Gearing:
I plan to utilize a belt drive based on 8mm HTD to gear down the motor 2.1:1 (38t front, 80t rear). I will CNC the pullies myselfe. A 20mm wide belt will have just enough clearance between the tire and frame. Last i plan to utilize the two speed gearing to shift the efficiency band to a lower speed for steep hills and or heavy loads, the low speed will also enable the use on normal roads with power limited via a CAv3. Shifting betwene the two speeds will in the end be handled via a microcontroler and a servo, with the shift point depending on speed and if max thrust is required (more than half throttle) och efficiency (under half throttle).
I wish the system to freewheel so a White industries eno will be mounted in the front pulley.
Battery:
24s lipo. (Before you say anything, i know it is on the edge for the 4110fets etc, but it should probably be ok with a high inductance motor, 240uH in high, And if it breaks i will have to learn how to fix it. )
89V nominal utilizing 6s turnigy 20C bricks. either 10 or 15 AH to be desised with a total capacity of 890wh or 1335wh.
BMS: Founding power programmable BMS with throttle intercept (LY.CS-bms).
http://endless-sphere.com/forums/viewtopic.php?f=14&t=40774
Probbebly a little to high energy consumption in passive mode, but enables the use of a monitoring display with temperature probe. A good idea for the control freak.
Breaks: Hygia multi, quite pricy but made for trikes and able to get with e-break and parking break. With a such heavy and powerful system i do not want to be a cheapskate on the brakes. Especialy when only having front brakes and no regen.
Rotors: Might be a little to much overkill with 2*203 floating rotors but with no real penalty in the terms of weight and price, so why not?
On the cheaper side for 203 floating but they have good user feedback, except being a little heavy.
CA: Picked up a V3 during the X-mas sale. Plan to use the tourqethrottle and temp limiting/monitoring. Will probably need to flash if with the latest firmware.
Battery compartment The plan is to print two "boxes" containing 6 (6 bricks fit comfortably inside printing volume) bricks each with the 3D printer i have access to (RapMan3). Shape and placement is yet to be decided.
Charger
Bought a used kingpan 1.2KW charger here on ES. Works but needs to be connected to an unused phase otherwise it trips the curuitbreaker.