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Project Electric (Push) Bike - Now With Video

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The Artist
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PostPosted: 22:57 - 16 Dec 2014    Post subject: Reply with quote

Aff wrote:
The Artist wrote:
Out of stock. Sad


Looks like it's in stock in their international warehouse.


Yeah, +£20 shipping over the top of £7 I am paying for the other stuff. I went with the other one so I have all the bits here over Xmas and can build it in my time off. Thumbs Up

I think once I get this built, I will have more ideas on what I want to do next regarding 2WD, larger custom battery pack etc. If you are running at 3KW, what sort of voltage is that at? Anything over 100VDC isn't too fun if you touch it.

Here is to hoping my disc brake is up to the job of stopping 150+kg's at 30mph Laughing
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Aff
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PostPosted: 10:00 - 17 Dec 2014    Post subject: Reply with quote

The Artist wrote:


I think once I get this built, I will have more ideas on what I want to do next regarding 2WD, larger custom battery pack etc. If you are running at 3KW, what sort of voltage is that at? Anything over 100VDC isn't too fun if you touch it.

Here is to hoping my disc brake is up to the job of stopping 150+kg's at 30mph Laughing


The 3kW was at 48V, the motor started getting a bit toasty at 60A though. Laughing

The new battery I have built is 72V, I probably wont be going much higher than this, I have vaporised quite a few things and electrocuted myself a number of times.

I will be running this motor at about 4.5kW and see how long it lasts. When I kill it I will buy a steel framed bike and make something beefy.

I completely killed my first set of brakes in a matter of minutes.
Swapped out to a 203mm disc and it's better but can still easily overheat them.
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The Artist
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PostPosted: 11:06 - 17 Dec 2014    Post subject: Reply with quote

What motor controller are you using? Also, more pics needed of everything. Laughing
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Aff
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PostPosted: 11:47 - 17 Dec 2014    Post subject: Reply with quote

The Artist wrote:
What motor controller are you using? Also, more pics needed of everything. Laughing


Think I have a Greentime controller at the moment, paired with a Cycle Analyst V3
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The Artist
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PostPosted: 19:49 - 18 Dec 2014    Post subject: Reply with quote

Shit is getting real.

https://i.imgur.com/p9N3MQY.jpg

https://i.imgur.com/XA9i5RG.jpg

https://i.imgur.com/p76fJyx.jpg

I only have 3 pairs of banana leads to go in the charger which is a PITA for now.

I have each pack charging @ 3A. The only bits getting warm are the DC wires going into the charger. The actual thick ones that go into the unit. My homemade 4x yellow and 4x black wires soldered together are cold. Bit confusing. Set the cut off point to 4.18V per cell as that is the lowest the charger does.

I should have a working bike by Monday so long as the forks I am getting fit my bike OK and my Anderson connectors arrive.
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Just_James
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PostPosted: 23:34 - 19 Dec 2014    Post subject: Reply with quote

Just in awe of this entire project! Shocked

All way over my head but just looks incredible! The homebrew spot welder is ingenious in its own right too! All very impressive Thumbs Up

I think the battery would look great if clear perspex or such was used, all that effort should be viewable and on display Very Happy
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The Artist
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PostPosted: 00:38 - 20 Dec 2014    Post subject: Reply with quote

Couldn't wait for the rest of my part to turn up so I bodged it together quickly for a test run. I am very pleased with the performance with just 1000W so can't wait to see what 2KW+ will be like.

Also, I might need to tidy the living room up a bit.

https://i.imgur.com/hQy2mAl.jpg

https://i.imgur.com/ouFJO0G.jpg

https://i.imgur.com/yaE3mC9.jpg

Big thanks to Aff and G for helping out with my no00bish electrical skillz. Thumbs Up
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kramdra
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PostPosted: 19:13 - 24 Dec 2014    Post subject: Reply with quote

Have been reading up on electric bike/rc bits. Very tempted to do something on my hybrid. My commute is 20 miles each way with some hills, so I very rarely use it Over this kind of distance my average speed drops down to 13mph or so. Eleccy should let me average 20-25 for not much cost.


Someone linked a guide not long - month or two ago, in random banter? it suggested lots of parts mostly hobbyking. I closed the tab and cant find it if anyone knows what Im talking about Sad

Motor likely to be RC type.

Id like it to be easily removable, so Im thinking a rack over rear wheel with a small box to put batterys and bits, with the motor driving the tyre.

Or motor driving a crank sprocket independent of pedals.
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Aff
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PostPosted: 17:06 - 30 Dec 2014    Post subject: Reply with quote

Found some more time for this.

Started to route the main power wires:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0198_zps98ca72e1.jpg

Terminating them with 45A Anderson connectors. I have seen multiple videos of people taking them to hundreds of amps with no ill effects, so I'm sure they will do me fine.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0199_zpsdbb5b0f2.jpg

Also wired in the charging wires:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0200_zps63e2550c.jpg

For the moment I will be leaving them like this, however it's almost certain that I will connect them up wrong at some point and make a mess. So I will probably put in a few more wires.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0201_mod_zpsee573e80.jpg

This is their first ever charge as a pack.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0202_zps244826d0.jpg

Starting with a conservative 10A charge just in case something isn't connected properly. All balance wires seem to be reading OK, which is a bonus.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0203_zps81156e19.jpg
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The Artist
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PostPosted: 17:19 - 30 Dec 2014    Post subject: Reply with quote

What is XSXP of that? Total capacity?

I have done most of my wiring with anderson connectors, makes everything so much easier. I should have all the bits to complete my MKI build by the end of the week.
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Aff
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PostPosted: 17:26 - 30 Dec 2014    Post subject: Reply with quote

The Artist wrote:
What is XSXP of that? Total capacity?

I have done most of my wiring with anderson connectors, makes everything so much easier. I should have all the bits to complete my MKI build by the end of the week.


18S10P.

Using an average of 2400mAh cells, 75.6V hot. About 1.8KWh.
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The Artist
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PostPosted: 19:49 - 30 Dec 2014    Post subject: Reply with quote

Aff wrote:
The Artist wrote:
What is XSXP of that? Total capacity?

I have done most of my wiring with anderson connectors, makes everything so much easier. I should have all the bits to complete my MKI build by the end of the week.


18S10P.

Using an average of 2400mAh cells, 75.6V hot. About 1.8KWh.


43Ah Cool

I am running 10Ah @ 45v. Although I am pulling about 27A through it so getting 1300W into the motor, not sure what sort of efficiency I am getting from there on.

EDIT: 24Ah (Doh). That doesn't seem like that much. What sort of range are you looking at?


Last edited by The Artist on 13:12 - 31 Dec 2014; edited 1 time in total
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Aff
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PostPosted: 20:18 - 30 Dec 2014    Post subject: Reply with quote

The Artist wrote:

I am running 10Ah @ 45v. Although I am pulling about 27A through it so getting 1300W into the motor, not sure what sort of efficiency I am getting from there on.


I find that relies mostly on your right hand and willingness to pedal. Laughing

I have been slowly cranking up the charge rate and the PSU keeps crapping itself at 30A output, its suppose to be 750W.

I'm gonna look out for a Server PSU, apparently should handle the prolonged high output better.
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The Artist
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PostPosted: 13:15 - 31 Dec 2014    Post subject: Reply with quote

Aff wrote:
The Artist wrote:

I am running 10Ah @ 45v. Although I am pulling about 27A through it so getting 1300W into the motor, not sure what sort of efficiency I am getting from there on.


I find that relies mostly on your right hand and willingness to pedal. Laughing

I have been slowly cranking up the charge rate and the PSU keeps crapping itself at 30A output, its suppose to be 750W.

I'm gonna look out for a Server PSU, apparently should handle the prolonged high output better.


Computer/Server PSU's are the way to go. Dedicated power supplies for this sort of thing have a massive premium for some reason.
I am not sure what current I am getting from my 430W PSU but I am getting ~11 amps (4x 2.xA @ 22.2V) out of my charger so I am happy enough for now.
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Aff
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PostPosted: 17:46 - 31 Dec 2014    Post subject: Reply with quote

Started mocking the bike up. All seems to fit fine so far.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0204_zps7277e9d7.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0205_zpsb569050e.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0206_zpsf92d490b.jpg
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The Artist
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PostPosted: 21:41 - 03 Jan 2015    Post subject: Reply with quote

Mock up no. 2 completed.

https://i.imgur.com/xgbJFxa.jpg

https://i.imgur.com/puLKxjk.jpg

https://i.imgur.com/lE4PPWT.jpg
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Aff
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PostPosted: 21:43 - 03 Jan 2015    Post subject: Reply with quote

Looking good buddy. Thumbs Up

Did you find the Voltage Displays at a good price in the end?
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The Artist
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PostPosted: 21:46 - 03 Jan 2015    Post subject: Reply with quote

Aff wrote:
Looking good buddy. Thumbs Up

Did you find the Voltage Displays at a good price in the end?


No. Cheapest I could find was £10 each but they are perfect and there isn't anything else that does what they do for that sort of price. Although when I go upto 8 batteries instead of 4, I am just going to have 4 low voltage monitors so if any of the cells drops below 3v, it will set off an alarm or something. These 4 are nice for real-time viewing for the time being.
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MG
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PostPosted: 12:50 - 28 Apr 2015    Post subject: Reply with quote

Any exciting progress on either of these?
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The Artist
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PostPosted: 17:54 - 28 Apr 2015    Post subject: Reply with quote

Nothing that exciting.

Now running 2kw on the rear. Added a key switch isolator and mounted the batteries in some aluminium box section so it looks a bit tidier.

Also, came up with a way to make my own ring terminals. (Temporary)
https://i.imgur.com/uZ2GkS1.jpg

https://i.imgur.com/uoBv7aS.jpg

https://i.imgur.com/m1xyDna.jpg
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kramdra
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PostPosted: 22:15 - 28 Apr 2015    Post subject: Reply with quote

Looks good, do you mount everything on the back?

I have been playing with Arduinos, waiting for hall sensors to arrive, but making a tiny bike computer with a couple of 1" oled screens.
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Pete.
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PostPosted: 11:06 - 20 Aug 2015    Post subject: Reply with quote

Watts the news on this Aff? Long time no update....
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Aff
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PostPosted: 12:45 - 20 Aug 2015    Post subject: Reply with quote

Pete. wrote:
Watts the news on this Aff? Long time no update....


House move and work means that this has been thrown in the corner and forgotten about. I might get around to looking at it again soon, but the battery I made is likely fubared and I'm not sure I can be bothered to deal with that. Sad
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