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Old 07-28-2011, 03:56 PM   #16
Luke OP
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Quote:
Originally Posted by Grider Pirate View Post
What motor are you using? Brushless?
Nice project!
It's an Agni brushed DC motor. Among the motors I could find that had the right amount of power it was the lightest. As a bonus, it's a lot easier to control than the brushless types, which makes things much simpler.

The Agni is rated for around 38 ft-lbs of torque for 5 seconds, which is similar to a 600cc 4 stroke. The continuous rating is half that, which will hopefully be fine in real use. The bigger problem is that there's no transmission, so I have to pick one gear ratio and stick with it.
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Old 07-28-2011, 04:04 PM   #17
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Originally Posted by earwig View Post
Sweeeet!!!!


What an amazing project, and the bike rides really nice already. I can't wait to see how it feels after some of your power delivery tweaks!

Luke, you are an inspiration. Majorly impressive accomplishment!


I need to mention that Earwig has graciously allowed me to work in his shop, which in addition to having much more space than my garage, has much more understanding neighbors.

Thank You.
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Old 07-28-2011, 06:00 PM   #18
Paul_B
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Awesome project!

What motor controller will you be using? I (and lots of others here I'm sure) would love more technical details and pictures.

This really is a cool project, best of luck.
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Old 07-28-2011, 08:31 PM   #19
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Cool thread.

I've only mucked with electric on a much smaller scale for RC Helicopters years ago (before Lith) but am able to follow you.

I thought building up an 18v pack of Nicads was a PIA ;-)
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Old 07-29-2011, 01:51 PM   #20
Mr. Fisherman
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I have been waiting for this one...
Great stuff....
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Old 07-30-2011, 01:06 AM   #21
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I got a little more work done on it today, and took a bunch of pictures.

The motor.



As mentioned before, it's made by Agni. It's a Permanent Magnet DC brushed motor. It's rated for 72V and 400 amps maximium. The output is up to 6000rpm and 38 foot pounds of torque.

Since 6000rpm is faster than I want to turn the countershaft sprocket, there is a jackshaft in between the motor and the wheel. The stock gearing is 13/47, I am using 11/48. Even then, the motor needs to be geared down so there is a primary reduction between the motor and jackshaft. I have a range of sprockets that can be used, currently it is 12/23.



There are a pair of parallel steel plates that hold the motor and jackshaft. They are welded together with spacers and attach to the stock motor mounts. The motor is bolted to another plate, which can slide a little on the main plate to adjust the tension on the primary chain.




Pardon the welds. Thin wall tubing and 1/8" stick aren't a great combination.



On to the electronics. The throttle is an off-the shelf part made by Magura. It even comes with a matching left side grip.





It can plug directly into the controller, but that makes things too easy.


The controller is made by Alltrax. It's good for 450 amps and a nominal 72V battery pack.



There's a relay and a fuse for safety. You could probably run the entire Touratech catalog off them.



Battery mounts without batteries:



It may look skinny, but it's not skinny enough. I'm still puzzling over how to fit twice as many batteries on this bike. I'd really like 2.5x.


And with batteries:




And of course, rider distractions. At the moment, they show motor and battery current and voltage.


And the battery charger. It's a bench power supply that's really nice for running the bike on a stand to test the electronics. Unfortunately it doesn't produce enough voltage to charge both batteries together, so I have to charge each separately. It takes about half an hour to charge each pack. With the best possible charger the batteries can be charged in 15 minutes.

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Old 07-30-2011, 01:23 AM   #22
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The stuff in the last post is the 'what you need' stuff for an electric bike. Here's a little about the optional extras.


Measuring the electrical current is nice, both to put numbers on distracting gages, and to make the control of the motor (throttle response) better.

I have two hall effect sensors. They're really easy to use: just run the wire through their core, give their electronics a little power and read the voltage they give you back.






And finally the control box. It has the power switches, some conditioning circuitry for the display multimeters, and some more circuitry to adjust the throttle.







For the first ride the bike had the throttle connected directly to the motor controller and the low speed response was a bit snatchy. The new circuitry fixes that, but it isn't right yet- it won't deliver full power on full throttle. Oh well. I'll fix that later .

I can do full lock turns now, which is nice. Sorry if it's boring, but I figure good throttle response is supposed to be boring.


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Old 07-30-2011, 01:38 AM   #23
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Quote:
Originally Posted by PhotoBiker View Post
Cool thread.

I've only mucked with electric on a much smaller scale for RC Helicopters years ago (before Lith) but am able to follow you.

I thought building up an 18v pack of Nicads was a PIA ;-)
Yeah, I'd love to be able to just solder them together and shrink-wrap them.

I gather that the RC crowd likes these cells too. They're only 2.3 ahr, but can put out 130 amps each for a few seconds, 70amps continuously.

The cells in my pack should be good for 650A in the short term, 350A continuous, although the wire and connecters can't handle that.
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Old 07-30-2011, 03:06 AM   #24
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Thumb Recharge system

Hi , this is a great build . I don't know much about electic motors , is it possable to put a recharging system on to get more milage while riding .It looks like you have some spare room to add on .
Thanks Tezza
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Old 07-30-2011, 04:48 AM   #25
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Very, very cool

Impressed... seriously impressed. You've put a lot of thought and effort into this. I hope you achieve all your aims...you deserve to.

Now...about riding not ATGATT.
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Old 07-30-2011, 04:23 PM   #26
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Very interesting...Hope you get it sorted
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Old 07-31-2011, 12:13 AM   #27
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Good work Luke .

Gonna be pretty bitchin when you get the kinks worked out

A left hand rear brake would be sweet
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Old 07-31-2011, 12:36 AM   #28
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Very cool build, cant wait for the trail shots.
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Old 07-31-2011, 07:25 AM   #29
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Looks great Luke. I love how it just takes off..and that electric power is just there - instantly.

Your electrical engineer skills kill be everytime, simply amazing.

Now, about the tape holding on the Harbor Freight multi-meters


Fantastic Build!!
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Old 07-31-2011, 12:29 PM   #30
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totally awesome. I would love to have a bike like this. I would love even more to be able to put anything like this together. keep up the great work.
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