Project Electric (Push) Bike - Now With Video

[Aff]

Just a quick test to see how this works, let me know what you guys think:

https://www.youtube.com/watch?v=YdP5Yvwp8us&feature=youtu.be
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Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[The Artist]

So how long till the police pull you over.

Looks awesome.

[Aff]

[Aff]

Picked up a few of these, gonna incorporate them into my dash when I get round to building it.

They are cell monitors. Have a really nice clear OLED display on them.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0636_zps5603ca22.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0637_zps224600d9.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

A few clips from my ride yesterday evening.

https://www.youtube.com/watch?v=sKzcUVsoEX0&feature=youtu.be
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

My chainring turned up from 'Murica:

https://i1135.photobucket.com/albums/m637/Biles/EBike/20140616_173317_zpsplgr0jdc.jpg

Just about fits on, But the old 44T large chainring doesn't fit in the middle, so I will have to run with 1 gear until I can buy a slightly smaller one.

https://i1135.photobucket.com/albums/m637/Biles/EBike/20140616_182612_zpszivvpmcp.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

OK so finally got round to the "mystery box".

The last set of packs I made were soldered together. This works but is VERY time consuming and is potentially damaging to the cells.

Large volume packs (laptop batteries, Tesla, etc) are made using Nickel Strip that it is spot welded to the ends of the battery.

Problem is spot welders are many hundreds of pounds, so I thought I might as well try and make my own.

So how I'm doing it, take a transformer out of a microwave:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0592_zps140c430b.jpg

So this transformer has a 240 turn primary and around a 2000 turn secondary to make it kick out about 2000V @ 0.4A.

I will replace the secondary with 2 turns so that it puts out about 2V @ 1000A.

The windings are epoxied into the core so to remove them you first need to split the core. It is welded together.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0640_zps8f4380ce.jpg

So first you need to grind off the weld.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0641_zps9d2c68ee.jpg

Then you can pry the "I" second of the core from the "E" section.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0642_zps6cc51314.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0643_zps3a87afc7.jpg

You then need to try to remove the primary coil. This needs to be done very carefully, if you remove the enamel from the magnet wire it can short out the coil and ruin the transformer. I done exactly this the first time I tried so had to buy another transformer.

I found the best was is to pack the gap with paper towels, then use a wide masonry chisel to pack them in, then keep packing more and more in until it comes out.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0644_zps57957af8.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0645_zps0e869c15.jpg

The secondary you can just pummel out with a hammer because it wont be used again.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0646_zps2f1f69a4.jpg

Which leaves you with the empty core.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0647_zps34123baf.jpg

These are you bits you keep ( and the "I" section of the core)

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0648_zps757667e2.jpg

Wrap in 2 turns of 4AWG wire:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0649_zps1cbf57a2.jpg

Put the shunts back in.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0650_zpsccc5618d.jpg

And the primary:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0651_zpsa0de83a2.jpg

That's the step down transformer complete. I will epoxy or weld the core back together when I finish the design for the welder.

I then cut some MDF:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0652_zps3be4517f.jpg

Mounted the base of the transformer.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0653_zps48969060.jpg

And mounted a 240V fan to help keep things cool.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0654_zps70b3dd47.jpg

Will get more done when I get some more time.

I would like to add that my knowledge of Electronics/Electrical stuff is extremely limited, I am Mechanical Design Engineer by trade so this magic electrical pixie stuff is all new to me. I know the fundamentals but please point out if I am about to kill myself.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[trisers]

How are you going to control the output current?

[Pete.]

I'd insulate the sharp corners on the 2-turns with mylar or something, or it might end up shorting if it get's hot enough to soften the insulation.

Also, be careful messing with microwaves, or this might happen:

https://www.youtube.com/watch?v=Wa07Mqpr32E
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Aff]

[Aff]

Started to model up a few bits a pieces.

18650 cell:

https://i1135.photobucket.com/albums/m637/Biles/EBike/18650_zpsabd343d8.png

Temp Gauge:

https://i1135.photobucket.com/albums/m637/Biles/EBike/TEMPDISP_zps18f7c273.png

Battery Spacer:

https://i1135.photobucket.com/albums/m637/Biles/EBike/BATTSPACER_zpsf6b61df0.png

24V 25Ah pack laid out how my original pack was:

https://i1135.photobucket.com/albums/m637/Biles/EBike/BPACK1_zps8a8b9c1a.png

Still undecided on the battery layout. I will be able to make a more informed decision when I have the frame modelled up.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[chris-red]

Would you consider to start doing kits? i.e. proving the charger controller and battery pack.

How much would it be?
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Aff]

[chris-red]

[Aff]

Progress.

The Arduino arrived. My shitty programming skills are even more shitty than I remember them being. Took me bloody ages to get some code that worked.

All I wanted was a single ~100ms pulse when I hit a switch, with no repeat.

Here is what I came up with in the end. If anyone has a better solution, please let me know:

[Aff]

Well I found some time to play around with the welders settings and we have success!

To start with I swapped the stupid Copper Plated Steel electrodes out for some solid Copper ones and profiled the ends.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_20140813_183423_zps8e858ddd.jpg

I then started trying to dial in the welding time. The welder is kicking out about 450-500A and I found a weld time of 127ms to give the best results.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0734_zpsa4ab87d1.jpg

When trying to rip the 2 pieces apart the welded metal stays where it is and the strip tears off around it, which is very good (better than some of the factory ones I found on the laptop cells).

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0735_zpsfc3d943f.jpg

My first weld onto a cell:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0736_zpsa4588b53.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0738_zps11060f0a.jpg

Worked nicely, and there was virtually no heat transfer, which is the main aim of this. Welds were cool to the touch instantly after welding.

So I put together my fist little pack:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0739_zpsdaea7ea1.jpg

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0740_zps0c204728.jpg

It's extremely strong. It would be very hard to pull this apart with your bare hands, and would probably just damage the cells instead.

I also done a test fit of the batteries on the bike:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_20140813_180501_zps50169de4.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[hmmmnz]

that looks awesome, are you going to cover the batteries??
perspex might be the go,
keep up the good work
____________________
the humans are dead
I kick arse for the lord
Wiring Diagrams BIDNIP it bitches

[Aff]

[Aff]

Got around to laying it all out properly. Managed to fit 180 cells in there, so just over 1.5kWh .

Getting the configuration right hurt my brain a bit.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0750_zps05134787.jpg

First welds done. Only a few thousand left .

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0746_zps82095a7d.jpg

First side connected up. This is 18 lots of 10P packs.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0748_zpse304802c.jpg

Both sides done.

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0751_zpsc8ad7412.jpg

And all the packs connected in series. Will come hot of the charger at about 75V. Took about 6 hours to do all the welding. I dread to think how long it would have taken to solder it all .

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0753_zpseaa945ab.jpg

So now just need to add 21 balance leads, 6 power leads and some temp sensors, then figure out how to mount it in the frame.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[chris-red]

You are either nuts or a genius. The balls it takes to hack apart a microwave, turn it into a spot welder then use it on batteries is huge IMO. The only thing I would have been unsure of, had I done it would be what would kill me first. Electrocution or explosion.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[The Artist]

This is glorious.

[Matt B]

[Ste]

How much does that thing weigh?

[Aff]

Forgot to update this. I have been doing a few bits and pieces when I get time.

Started to lay out the balance wire routing, It gets a bit cramped when you have to route this many:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0758_zps22763fef.jpg

While doing this, the mechanical relay on the welder gave up, giving about 50 welds to the top of one cell. This eneded in a Lithiumey mess, no 'splosions though.

I replaced the mechanical relay with a solid state one:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0772_zps3c61b039.jpg

Then glued the balance wires in their final positions:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0773_zps12321e6b.jpg

And added the connectors:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0774_zps464732d0.jpg

I have started to add the main power wires, still need to figure out where they will all go. I'm using 10 gauge high flex silicone wire:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0775_zpsda0c6d54.jpg


Ste, weight is pretty good:

https://i1135.photobucket.com/albums/m637/Biles/EBike/IMG_0776_zps31cfb9b0.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[bladerunner]

Be jeezus .....have you seen the film "fastest Indian"? This is like the modern day version looking very neat I must say
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Current bikes...cbr929, KDX200's, Rd125lc mk2, RGV250's