Brompton electrification

[cwah]

Quick update on my brompton:
- Purchased a spare 72V 45A controller from zenid:

Zenid e-Bike Parts

Received it within 2 days (in the UK). It doesn't have regen or can't be configured, but it's a very good spare controller.

- Put my battery in a camera bag:

 

[cwah]

Here is the folded brompton:

It rolls!!!

It goes fast too. I don't have a speedometer on the brompton yet (as the cycle analyst plug wasn't compatible), but I think I'm around 25-30mph.


Almost there. The controller is not that stealthy... I may put it inside the bag. Not sure how to solve that yet.

 

[flecc]

With my actual batteries, I'd be around 20-23mph. So no worries

Just make sure you never collide with anyone cwah. If you do the police will definitely prosecute and convict you. It won't only be on the tested assist speed of 20 to 23 mph, it will also be on the 72 volts, since the Construction and Use Regulations only allow 48 volts maximum for e-bikes.

 

[cwah]

yes, I'll be careful!

Actually I don't know at what speed I'm running now, but I woudn't want to run any faster. The small tyres don't grip that well on the ground.

I'm probably much slower than I think but with these small wheels it looks like I'm going so fast. I will do a report as soon as I know what's the exact speed at this voltage.

 

[cwah]

Thanks. Going to see how I can enable regen

Quick field report from today cycling:
- I'm actually cycling slower than usual because I don't want to go too fast. Going fast on these small wheel seem dangerous. Some cyclist are faster than me, I think I'm taking too much precautions :lol:


Otherwise, in term of stealthyness, it's not there yet at all:

Everybody noticed it was an electric bike. Have been stopped 3 times in my little driving tour:
- Asked me twice about the bike price. I lied (costed me £300 bought it second hand)
- Asked me advice about electric spare
- And 1 guy said "look, an electric bike".

Even though the controller has the frame colour, it's not stealthy at all. It definitely has to be inside the bag

 

[oigoi]

Good to see the project has come together for you cwah, hope it keeps working well

 

[cwah]

Yeaaaaah, I'm so thankful of all of you guys. Would never achieve that without all your help

 

[danfoto]

What on earth are those orange things at the base of the tree trunks in the background of your snaps?

 

[cwah]

Not sure what it is lol. Can check that tomorrow

 

[cwah]

I'm thinking about moving all my connectors from my controller to an unique connector:
D-SUB 37 Pin Female Solder DB37 Type Connector x 10 Pcs | eBay

Could work for everything except for the batteries. So I'd have this multiplug connector + batteries/phase wires connectors together. Would that work?

 

[johnc461165]

Well done cwah, good to see your progress with the Brompton, so glad to be of help to you in your project and best wishes to your future progress with the bike. John

 

[NRG]

I'm thinking about moving all my connectors from my controller to an unique connector:
D-SUB 37 Pin Female Solder DB37 Type Connector x 10 Pcs | eBay

Could work for everything except for the batteries. So I'd have this multiplug connector + batteries/phase wires connectors together. Would that work?

Noooo, motor phase would draw too much current and how would you water proof that connector....

How many connections do you need to make?

These are good for Phase wires and other connections, water proof and with a high current rating....

water proof car connector | eBay

Largest is only 6 way though....

 

[cwah]

Well done cwah, good to see your progress with the Brompton, so glad to be of help to you in your project and best wishes to your future progress with the bike. John

Thanks John, without your help I wouldn't be able to complete this project.
Now it's time to make the bike work better.

 

[cwah]

Noooo, motor phase would draw too much current and how would you water proof that connector....

How many connections do you need to make?

These are good for Phase wires and other connections, water proof and with a high current rating....

water proof car connector | eBay

Largest is only 6 way though....

Yes, I'm planning to have another connector for the phase and the batteries plugs. Something such as a 5 pins 45A connector.

But I have a lot of connections for the controller:
- Cycle analyst direct plug : 6 pins
- Brake: 4 pins
- Hall sensors: 5 pins
- Throttle: 3 pins
- Regen: (don't know how that works yet)

So minimum 20-24 pins connectors. Best would be to find something waterproof, but if it's not I can still wrap it when it's raining.

 

[flecc]

What on earth are those orange things at the base of the tree trunks in the background of your snaps?

Possibly to stop dog pee onto the base of the tree trunks?

 

[cwah]

Guys, I may have found my connectors:
5x pairs MPX connector plug 24K gold 6-pin 40A RC LiPo | eBay

Really small, and able to handle 40amps. There is a good area to glue them together, maybe I can even have only 1 plug!

 

[NRG]

Guys, I may have found my connectors:
5x pairs MPX connector plug 24K gold 6-pin 40A RC LiPo | eBay

Really small, and able to handle 40amps. There is a good area to glue them together, maybe I can even have only 1 plug!

Really good find!

 

[cwah]

Thanks. Just purchased them with the 25 pins DB connectors. Will see what they worth

 

[muckymits]

Ive been looking for an 8 pin water proof connector (balance lead) but no joy yet. Any ideas any one?

 

[cwah]

This one is a 9 pins cable for motor:
A pair of 9Pin Waterproof Male/Female Connector Cable for Motor - BMSBATTERY