So I have been playing with the Motor Simulator quite a bit, to see if I can make up my mind on a few design parameters...
In my previous attempt, as Rix stated, I chose the 66V Dewalt from the list of available batteries purely for the "Speed" of 66V, which gave me a 4 mile range, as ZeroEm pointed out.
So here are a few comparative simulations (changing only one thing each time) which are starting to give me some direction:
3T vs. 4T , 66V battery, 100% Throttle in Voltage mode ===> 3T just has a nicer torque curve!!
https://ebikes.ca/tools/simulator.html?motor=Leaf%205T&mass=150&hp=0&batt=cust_66_0.02_22&wheel=24i&frame=mountain&axis=mph&blue=Nm&cont=cust_100_240_0.01_V&throt=100&kv=17.49&cont_b=cust_100_240_0.01_V&motor_b=Leaf%205T&batt_b=cust_66_0.02_22&wheel_b=24i&mass_b=150&hp_b=0&kv_b=13.11&bopen=true
3T vs. 4T, 66V battery, @35MPH (Desired cruising speed) Throttle adjusted in Voltage mode ===> 4T Starts with just TOO much!!
https://ebikes.ca/tools/simulator.html?motor=Leaf%205T&mass=150&hp=0&batt=cust_66_0.02_22&wheel=24i&frame=mountain&axis=mph&blue=Nm&cont=cust_100_240_0.01_V&throt=53&kv=17.49&cont_b=cust_100_240_0.01_V&motor_b=Leaf%205T&batt_b=cust_66_0.02_22&wheel_b=24i&mass_b=150&hp_b=0&kv_b=13.11&bopen=true&throt_b=70
At this point I am really leaning toward a 3T motor (Max copper fill, etc..) Now, figure out the battery!!!
Both 3T, 72V vs 66V, @35MPH (Desired cruising speed) Throttle adjusted in Voltage mode ===> +6V improves range by 6 miles??
https://ebikes.ca/tools/simulator.html?motor=Leaf%205T&mass=120&hp=0&batt=cust_72_0.01_22&wheel=24i&frame=mountain&axis=mph&blue=Nm&cont=cust_100_240_0.01_V&cont_b=cust_100_240_0.01_V&motor_b=Leaf%205T&batt_b=cust_66_0.2_22&wheel_b=24i&mass_b=120&hp_b=0&bopen=true&throt_b=58&throt=48&kv=17.49&kv_b=17.49
Both 3T, 66V vs 60V, 100% Throttle in Voltage mode ===> -6V, Top speed drops by 1.6mph but still over 50mph!
https://ebikes.ca/tools/simulator.html?motor=Leaf%205T&mass=150&hp=0&batt=cust_66_0.02_22&wheel=24i&frame=mountain&axis=mph&blue=Nm&cont=cust_100_240_0.01_V&throt=100&cont_b=cust_100_240_0.01_V&motor_b=Leaf%205T&batt_b=cust_60_0.02_22&wheel_b=24i&mass_b=150&hp_b=0&bopen=true&throt_b=100&autothrot_b=false&kv=17.49&kv_b=17.49
Both 3T, 66V vs 60V, @35MPH (Desired cruising speed) Throttle adjusted in Voltage mode ===> The extra 6V just doesn't add much!
https://ebikes.ca/tools/simulator.html?motor=Leaf%205T&mass=150&hp=0&batt=cust_66_0.02_22&wheel=24i&frame=mountain&axis=mph&blue=Nm&cont=cust_100_240_0.01_V&throt=53&cont_b=cust_100_240_0.01_V&motor_b=Leaf%205T&batt_b=cust_60_0.02_22&wheel_b=24i&mass_b=150&hp_b=0&bopen=true&throt_b=58&autothrot_b=false&kv=17.49&kv_b=17.49
I have seen it stated different times, that Kelly Controllers rate their controllers differently than other companies because they use motor amperage's????? I don't know what to do with this info, so the 100A continuous, and 240A max phase amps I used in the motor simulator are Kelly's advertised numbers for their KLS6018S???? Was that the right thing to do??
If the "custom controller" numbers used are correct, then I think the recommended 3T motor is the way for me to go!! As far as a battery choice, I think around 60V seems to meet my original stated requirements... A few less cells in series, might be able to be used for more range!! Which brings me to my Range question of the day...
Can anyone tell me how the real world range of their build compares to the range the motor simulator predicted before the build?? Or are there other tweaks to the motor simulator I could do to make the predicted range more realistic?? (Yes, I know I have not input any human power... I am going to consider that a bonus).
Thanks for following along!
Keith