Chaplain said:
Twice a year I haul a photographer around the island to cover either the Honolulu Marathon or the Dick Evans bicycle race. The bike race is about 175 miles from the time I leave home till I get back home. That's about the farthest ride there is here. Occasionally, I do a double back but it is still almost always under 200 miles. My wife likes to ride with me, hence the 2up. If I had the money, I would just buy a new ride, but that is more than I can swing, at least for now.
I want to be able to have my wife hop on and we go for a 100-mile ride without having to charge up halfway around the island (Oahu).
Plenty of battery is pretty much the only real option I have right now. I have a windshield already and it helps the mileage, but I never measured to find out how much.
I am looking at a belt from the motor to the wheel, a 1:1 gear ratio and just program it slower than the 6000 rpm the motor is capable of. Using a reduction just makes no sense to me because it wastes power in the gears, and the motor uses less power at lower RPMs anyway. The motor already has torque coming out its ears, unlike a gas hog which has to get up to speed to have any real torque. So why the gear reduction system?
I don't want to sound too harsh, but it seems like you have no clue at all regarding the project you plan.
You really need to spend some time reading everything you can on this forum, there's a lot of things you don't seem to get yet.
Solar panels: useless, you'll get maybe 200W of power max if you cover the entire surface of your bike, which would look ugly as hell too.
Windmill: totally useless, you will end up spending more energy to make it turn than it will give you back, so it's only good if you plan on losing range.
Generator: Much better to save that precious space for a bigger battery.
Let's say your generator outputs an impressive 2KW (that would be amazing already). That means, if you plan on riding for 2 hours, that you'll have charged your battery with 4KW of juice. Nice.
Problem is, your generator will be quite big (let's imagine its some kind of lawnmower motor, with an alternator and a voltage converter/rectifier). In my opinion, this whole thing will be probably equal if not bigger in size compared to a 4000W battery block. So it's just better to put this battery in there in the first place.
The only way I could see for a generator being actually useful would be if you found a gas turbine, but that's not really realistic.
Gear ratios: I don't think you understand how belts work, the losses are the same wether its 1:1 or 1:5 or 5:2. Also, what matters is not the power output of the motor at a given RPM, but its efficiency. And it's not great at all at low rpms usually. I don't recommend you an inboard motor anyway, there's no advantage in your situation.
Autonomy: Getting 200miles at highway speed (60mph) is not entirely unrealistic, but close to be. From my approximate calculation, you would need a battery power of around 16 000 Wh at the very, very minimum. Surely even more if you ride with your wife. IMHO, realistically, it would need probably 20KWh. That might be
really huge. Your bike's chassis is quite big, but I'm not really confident you can actually squeeze that much battery power in it. The tank being a bit small and oddly shaped, I think you should forget putting batteries in there. Maybe you could fit in the controller instead.
Cost: I think that if you plan on spending less on an electric bike of these specs than a gas bike, you're likely to be very disappointed. It will likely be much more expensive, especially if you need such a giant battery pack.
A good hub motor might cost around 2000 dollars, a good controller will be at the very least 800 and I have no idea about how much will cost the battery wherever you live, but I guess it will be more than 5000 bucks. And those are quite conservative figures in my opinion. Add also the cost of a charger, of various little parts and it might be much more expensive than gas bike, with lesser specs.
If I had to build this project "properly", I'd go for this motor:
http://www.cnqsmotor.com/en/article_read/QS%20Motor%2017X4.5inch%2012kW%20273%2070H%20V3%20Water%20Cooled%20Electric%20Motorcycle%20Hub%20Motor/423.html
I'd take the watercooled version because it would likely need that to withstand high speeds for a long time period, plus 2 people on a bike will create quite a bit of heat during takeoffs.
About the controller, not entirely sure in that power range but at least something like a Mobipus 600 or, preferably, some equivalent from another brand (Kelly, APT, Sevcon, whatever). Here again, watercooled.
About the battery, I think the only way is to go for the best possible li-ion cells here, I'm not so familiar with those since I prefer using LiFePO4. Regarding the pack voltage, 84V or higher would be better if you plan on reaching high speeds more efficiently, so you can avoid using flux weakening.
Anyway, no offense, but I'm fairly certain this project is not achievable for you today, you need to learn a great deal of stuff first before attempting something like that, it's not an easy build even for experienced builders. Anything is possible, it's certainly not rocket science, but take your time to really understand every bit first
We'll gladly help you anyways, wish you the best in this project!