Hello From Stafford - ANYONE FROM STAFFORD?

[Captn Pythagoras Barnaby]

Hello All

I'm an engineer working for Alstom in Stafford.

I bumped into one of the forum members at the train station the other day, I think he was running a 36v 9ah fwd direct drive hubbie on a hardtail.

I think it would be great to have a hackspace for electric bikes in stafford as it would bring more awareness for the usefulness electric bikes can bring.

I'm receiving my electric bike today from my friend who is a welder after he finishes the dropouts, I will post some pictures later of what I am planning to build. I look forward to people's input.

also, please note that I believe in lots of power , so I hope to share my experience of building a high powered electric bike with this forum.
many thanks
Adam

 

[mountainsport]

also, please note that I believe in lots of power , so I hope to share my experience of building a high powered electric bike with this forum.
many thanks
Adam[/QUOTE]

We all like a bit of power, which I am not ashamed to admit. Lets see these pictures soon.

MS.

 

[Captn Pythagoras Barnaby]

 

[Captn Pythagoras Barnaby]

photos uploaded
Modded shunt on the controller to carry 425A
Modded capacitors to 200V low ESR
Battery:amp20ah 3.6v lifepo4 28series 1p
voltage: 95.7v
Amps: 500A pulse 300A continuous
Wattage: 40,672w
Modded 3 speed switch, 250W on road, 10kw for offroad, 40kw for flight mode .

Current problems: CNC'ing a freewheel onto the motor plate to allow for chain.
2) chain clearance not clearing bike rear tyre
3)crank not 200mm wide (more like 110mm) so chain alignment issues require transmission belt
any helpful advice would be appreciated before I start down the road of cutting up the motor sleeve

also, please note that I believe in lots of power , so I hope to share my experience of building a high powered electric bike with this forum.
many thanks
Adam

We all like a bit of power, which I am not ashamed to admit. Lets see these pictures soon.

MS.[/QUOTE]

 

[Deleted member 4366]

Could you mount a jack-shaft behind the bottom bracket to carry the free-wheel and a disc brake on the other end? Then you could mount a permanently engaged drive sprocket well outboard. It's a shame you've already done the frame. It could have had the disc in the middle, left-hand free-wheel on the left side with the crank turned round to the other side, and the drive sprocket on the right side, or turn the motor round for a right side crank and free-wheel.

I hope you can get a launch control system for that because it's going to need it. It's hard enough launching 4 kw without wheelying.

 

[Captn Pythagoras Barnaby]

It's a shame the controller cannot be programmed, so it's a question of hairtrigger throttling or placing the batteries on the front forks.
as for mounting the chain, I think that might be an option to swap the sides of the sprocket, I will take measurements tomorrow and see if I can fit this into the frame.
yes it's a shame i finished the frame.

I hope you can get a launch control system for that because it's going to need it. It's hard enough launching 4 kw without wheelying.

 

[Deleted member 4366]

The Cycle Analyst can add a ramp profile to the throttle for safer starts. They offer an additional shunt that can take up to 800 amps, or there's a guy on Endless Sphere called Gwhy! who has made some powerful bikes. He used a small PICAxe chip to do his. It was very neat. If you send him a message, he'll give you the schematic and the code. He'll probably share some other ideas too.
Endless-sphere.com • View topic - its now a e-motorcycle

 

[funkylyn]

View attachment 6118View attachment 6119View attachment 6120View attachment 6121View attachment 6122View attachment 6123

WOW.......well, what can I say except,

1. that certainly looks different,
2. you are obviously much more techie than me
3. personally I prefer my power in my car......

4..... and Im sat back waiting to read the comments that are sure to come powering in ...........

Lynda

PS.......you taking that to Bristol hill race tomorrow ?......just a thought......roflol

 

[Captn Pythagoras Barnaby]

Thank you for your comments lynda

today I'm taking it out for a ride if anyone in stafford wants to meetup?

yesterday I had to swap the sides of the motor to fit the sprocket I am mounting so unfortunately, as of now I need to figure out the 'reverse' of the current power phases.

(the other problem is keeping all that power down on the ground)

I've ordered a second controller soon to split the power between six phases. the plan is to run twin controllers to break the current between both banks of mosfets, solder the shunts and silver solder and insulate all connections for low resistance.

just for a laugh here are some stats so far in offroad mode:

0-60mph in 5.7seconds
top speed is 103mph
using two 36 fet irfb4115 controllers at 126v with a single throttle:
0-60mph in 4seconds
top speed is 113mph

running 70kw peak.

WOW.......well, what can I say except,

1. that certainly looks different,
2. you are obviously much more techie than me
3. personally I prefer my power in my car......

4..... and Im sat back waiting to read the comments that are sure to come powering in ...........

Lynda

PS.......you taking that to Bristol hill race tomorrow ?......just a thought......roflol

 

[Captn Pythagoras Barnaby]

I never knew... thanks for the info...

Do you know anything about the GT power shunt mod? is that any good? would it be able to handle (by using an external shunt for 500A) 4Guage welding cable?

The Cycle Analyst can add a ramp profile to the throttle for safer starts. They offer an additional shunt that can take up to 800 amps, or there's a guy on Endless Sphere called Gwhy! who has made some powerful bikes. He used a small PICAxe chip to do his. It was very neat. If you send him a message, he'll give you the schematic and the code. He'll probably share some other ideas too.
Endless-sphere.com • View topic - its now a e-motorcycle

 

[Deleted member 4366]

You'd be better off asking these questions on Endless-Sphere, where there's masses of information on every type of electric vehicles. This forum's more for electric bicycles.
Endless-sphere.com • View forum - E-Scooter and Motorcycle General Discussion

 

[Gdread]

Hi Adam

It was me the other day, great to meet you! I had that image of the photo of your bike in my head all the way home -----wow!

I'm not surprised to see where you work! If the power dims in the town one night and there's no mushroom cloud then I guess you'll have got it working!

 

[OldBob1]

Hi Adam please let me know when you next test it, use to do work in your place of work, there was some knowledgeable people working there then!
Might have my beastmatic type folder going by then!!!

Bob

 

[Captn Pythagoras Barnaby]

Awesome!

Forgot to mention that I've got some problems with the spacing for the freewheel and some chain alignment issues to iron out, will upload pictures, it's like a 130mm chain mis-alignment which is probably the biggest problem in this very straightforward project ...I'm talking to my welder friend who's going to work on it today.

Will post up pictures as soon as i'm back today.

Hi Adam

It was me the other day, great to meet you! I had that image of the photo of your bike in my head all the way home -----wow!

I'm not surprised to see where you work! If the power dims in the town one night and there's no mushroom cloud then I guess you'll have got it working!

 

[Captn Pythagoras Barnaby]

Hi OldBob

I'm finishing some parts up on the bike to get it ready for the summer.

1) I need to locate the batteries securely under the downtube and on the sides or on either side of the front forks( with a low COG better acceleration), and preferably not too far from the motor with as short cables as possible, and I can't decide whether to install them in front panniers, or in the frame? any thoughts?

2) Need to shorten all the cables to decrease resistance, voltage drop is currently 95.7--->78.4v with 400A draw so each cell's dropping to it's lowest 2.8volt per cell onload! not good!

3) 400A * 78.4 = realistically putting out around 31 360 watts (down 10KW from 40,000W) add some losses probably around 29kw... this has to be improved massively with double guage low-loss cable.

4) considering a solar panel bodypanel jobby for individual cell balancing New upgraded 1W flexible solar cells of amorphous silicon can foldable very slim solar panel 2V 660MA for Diy,phone charger-in Solar Cells, Solar Panel from Electrical Equipment & Supplies on Aliexpress.com

Hi Adam please let me know when you next test it, use to do work in your place of work, there was some knowledgeable people working there then!
Might have my beastmatic type folder going by then!!!

Bob

 

[Gdread]

Battery position is going to be best out front? May keep that front end down?

At 130mm offset you are either going to need a big spacer on the back wheel with support bushes or a deep dished chain wheel or a widened bottom bracket and crank set. I assume pedals are needed for 'stealth mode'?

 

[Captn Pythagoras Barnaby]

stealth mode will prove necessary in the long run ))
two battery boxes welded slightly below the tubular frame where the downtube meets the headset, and one steel box slung underneath them both with hinged catches and some pannier bags covering it all front and back?
look what came in the post today
I think I'm going to mount this in the well between the headset and column, or the front end of the bike. I

Battery position is going to be best out front? May keep that front end down?

At 130mm offset you are either going to need a big spacer on the back wheel with support bushes or a deep dished chain wheel or a widened bottom bracket and crank set. I assume pedals are needed for 'stealth mode'?

 

[Gdread]

How's this for a body work idea! ..........


That starter panel looks cool, mounting the batteries on the frame will help the loss through the cables?


Could you use an intermediate shaft for the chain, not sure what the correct term is but maybe mount a freewheel on a lay shaft on inboard side of the chain stay and then use that to offset it further to line up with the rear sprocket? You could weld on or clamp on a bottom bracket and use a bb unit to create the lay shaft?

 

[Captn Pythagoras Barnaby]

I was laughing in the office about the wheeliebar idea
that's awesome for a fairing! I wonder what the fuzz'll say about all that with the wheeliebar it'll take some explaining hahaha

I should build some extra downforce and maybe some stealth flat spaces in the frame using the battery cases at an angle should give this at the higher speeds, maybe if I mounted the controller at a 45degree angle that would help matters slightly

I've had a change of plan and am going to stick to 1 36 fet controller as the 450A is adequate.

I'm looking for serious disc brakes from the KTM 125cc's along with the calipers for the front and rear, braking is a problem right now

unless I figure out how to adjust the e-abs inside the controller.

 

[Gdread]

Maybe mount the pv cells under a clear Plexiglas or polycarbonate fairing?