Brompton electrification

[NRG]

Now I see how large they are I'd say they are not safe cwah...there's no provision for proper strain relief and I doubt the current rating for them is anywhere near 35amp. I'd replace them immediately, far too risky to use them as they are...

 

[cwah]

Yes, I think it's too dangerous too.

I changed it with DB25 connectors:

It accepts 5A/pin. So 5 pins for the battery cables (25A) and 3 pins for the phase wires (15A). And at least 1 pin distance between each to prevent short

Hope it's going to work.

 

[cwah]

Ok, bike seems to be working on low amps. I'll probably have to limit the amps of the controller to 30A to prevent the pins to melt.

I've seen some sealing glue on wires:

I'd like to add that to my wires too to seal them. (and potentially make it waterproof).

Is that thing the silicone caulking sealant?

http://www.amazon.co.uk/Everbuild-450CL-Builders-Silicone-Sealant/dp/B001GU6CNM/ref=sr_1_6?s=diy&ie=UTF8&qid=1335005288&sr=1-6

 

[wurly]

If you want to seal the leads into a connector shell. Wrap some insulation tape around the connector and fill it with a 2part mix 'araldite' (i think that is what is used on the connectors in your photos), only make sure you have the leads soldered to your satisfaction because you won't be able to remove it afterwards. Builders silicone isn't really strong enough.
I don't believe those d connectors will be able to handle high current either. They designed for small voltage signals.

 

[cwah]

Thanks Wurly. Is araldite are a good seal like the silicone gel?

I think I've found the right connectors finally:

eBay - The UK's Online Marketplace

They are made for AXT power supply that can handle 1000W and more. That should be able to handle high current

 

[neptune]

Caution. You will find that builders silicone smells like vinegar. That is because it contains acetic acid. Do not use it where it can come into contact with metals or wires, as it will cause corrosion.

 

[flecc]

Caution. You will find that builders silicone smells like vinegar. That is because it contains acetic acid. Do not use it where it can come into contact with metals or wires, as it will cause corrosion.

Indeed, this should never be used around electrical connections, only really safe with plastics and ceramics. Araldite is fine, either the rapid or slow curing kind.

 

[cwah]

Thanks guys, going to get Araldite then

 

[cwah]

Actually, I've also seen this sort of "silicone sealant" on my controller cables exit. Both on the Hua tong one and the Infineon.

This item specify it's a sealant for cable:
BURST BRICK BLAST CABLE COVER WALL HOLE PLATE WHITE WITH SILICONE SEALANT | eBay

And cables are also made of silicone. So why is it a problem? And why is there this sealant on the controller if silicone sealant shouldn't be used?

 

[NRG]

I think theres a small issue if it touches bare metal before its cured. As you have used heat shrink tubing on the wire cwah I doubt theres any problem. I've used the same stuff on my connectors and not had an issue.

 

[cwah]

Ok, will try to cover the metal to the maxium. Maybe the sillicone can work if it's already used on controller wires.

 

[flecc]

Indeed, it's only where it's in contact with metal that silicone sealant can cause a problem, as I remarked above, safe with plastics.

 

[vhfman]

Not all silicone sealant has acetic. You can get non acidic non corrosive silicone sealant, like the RTV sealer you should be able to find some on febay.


Chris

 

[cwah]

Thanks.

Is this one the right sealant?
PRO SEAL RTV Silicone Instant Gasket RED 85g Hi-Temp sealant | eBay

 

[cwah]

Update on the brompton:
With my little conhismotor mini hub at 4.6 kg, I do peak at 2500W and he handle it without breaking a sweat. But I only use that much power for acceleration and I don't cycle very fast (17-23 mph).

I'm actually running slower than my actual "limited power" bike. Most cyclist are faster than me but I'm more careful about security than going faster than them.. And I know I'm way faster


I believe with great power comes great responsibility


However, my mini direct drive motor is really really power hungry. I only cycle around 17-23mph but I'm using around 18wh/km. That's huge.

At 500W continuous I'm around 25kph. That's not really efficient. Not sure if it's because of the high voltage, leading to the low efficiency band of the motor..

 

[cwah]

My brompton is following me everywhere!!

Soreditch:

Oxford circus:

Picadilly:

 

[cwah]

When I came back this evening to pick up my bike, I've seen a secret admirer for my bike:

Unfortunately, it's not for sale

 

[Synthman]

When I came back this evening to pick up my bike, I've seen a secret admirer for my bike:

Unfortunately, it's not for sale

I wouldn't trust anyone who writes a message like that on a bookies slip! They could have filled out the total stake at least!

 

[cwah]

And it's a Ladbroke paper. He's betting on something