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1198
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PostPosted: 17:19 - 24 May 2020    Post subject: Reply with quote

I think Tesla, Toyota and all the other successful manufacturers need to employ this ‘wizened old electrician’ immediately. He obviously understands the problems of electric vehicles much better than their multi million pound development engineering schemes ever will...






......and they’ll have (unnecessary) gearboxes too!
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TravisBickle
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PostPosted: 19:15 - 24 May 2020    Post subject: Reply with quote

1198 wrote:
I think Tesla, Toyota and all the other successful manufacturers need to employ this ‘wizened old electrician’ immediately. He obviously understands the problems of electric vehicles much better than their multi million pound development engineering schemes ever will...






......and they’ll have (unnecessary) gearboxes too!


ROFL
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st3v3
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PostPosted: 16:27 - 25 May 2020    Post subject: Reply with quote

Paddy. wrote:
Ever wondered why people don't think before posting?
Laughing



My ebike (cycle) works really simply, it's either on or off, and the controller changing the rate of off and off every 20th millisecond gives me the constant speed; why would it need a gearbox if the speed is constant based on throttle being on or off?
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Robby
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PostPosted: 17:48 - 28 May 2020    Post subject: Reply with quote

If you have a small, revvy bike then you need all 6 gears to make use of it. There is little torque low down, and the torque spread is narrow. Same for 2 strokes, that you have to keep on the boil.

Big-engined cruisers with a lot of torque can get away with less gears, and a lot less gear changing. Stick in 4th and ride.

Electric bikes have something like 5 times the torque of a big-engined cruiser. So they are fine in top gear.

Whilst there may be some small efficiency improvements from using a gearbox in some cases, they aren't enough to justify the cost, weight and friction penalties. That's space and weight that could be used for more batteries.
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Coby
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PostPosted: 21:36 - 07 Jul 2020    Post subject: Reply with quote

Possibly true, but more batteries weigh a lot as well.

Smaller motor, less batteries and a gearbox might be more fun.
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Kawasaki Jimbo
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PostPosted: 22:01 - 07 Jul 2020    Post subject: Reply with quote

But range? You continue to suppose that manufacturers have deliberately chosen to use sub-optimal designs because they haven't thought it through like you have. Seems unlikely doesn't it?
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Coby
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PostPosted: 09:15 - 08 Jul 2020    Post subject: Reply with quote

They're Americans!
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Easy-X
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PostPosted: 12:36 - 08 Jul 2020    Post subject: Reply with quote

Coby wrote:
Possibly true, but more batteries weigh a lot as well.

Smaller motor, less batteries and a gearbox might be more fun.


Reduce weight with less batteries, okay...

Add weight with unnecessary gearbox, err....
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Easy-X
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PostPosted: 12:44 - 08 Jul 2020    Post subject: Reply with quote

Just trying to drag this thread back to some semblance of normality I did wonder how much of difference it would make if you took the lightest race bike you could find, add on the lightest motor (probably 250 to 350W wheel hub motor) and then run a minimal battery.

For a 36V battery you'd have at least 10 cells in series. However the current output wouldn't be enough to supply a motor's needs so it's usual to run 3 or 4 parallel banks of cells. If one were to use high output cells (decent branded Sony, Samsung, etc.) you might get away with a 10S2P pack (2 parallel banks of 10.)

If a typical cell weights 50g that's half a kilo saved! Woohoo!!!

Yeah, probably better to eat less pies Rolling Eyes
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dynax
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PostPosted: 12:44 - 08 Jul 2020    Post subject: Reply with quote

Just mount a bloody generator to power the motor, no law to say you can't use an engine to supply electric there is no direct drive between the engine and bike, and 8+ hours of running time off a tank Laughing
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Coby
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PostPosted: 13:13 - 08 Jul 2020    Post subject: Reply with quote

The Zero (I think that's the name) still has a crap distance coverage per charge (maybe 110 miles from memory), unless you 'double' the size of the battery bank!

That's got to add a lot of weight (and cost I believe).
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Easy-X
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PostPosted: 17:41 - 08 Jul 2020    Post subject: Reply with quote

Coby wrote:
The Zero (I think that's the name) still has a crap distance coverage per charge (maybe 110 miles from memory), unless you 'double' the size of the battery bank!

That's got to add a lot of weight (and cost I believe).


Most people don't get hung up on it but dirt bikers have a long hard think about tearing off their plastic tanks to put on an extended range one.

Nothing for free in this life!
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Campbell SOUP
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PostPosted: 23:22 - 08 Jul 2020    Post subject: Reply with quote

Coby wrote:
Star delta starters went with the dinosours. We have proper control of motors with inverter drives now. Technology moves on...


Andy


Referring to a star & delta starter, along with 3 x Types of circuit breaker was just an easily understandable way of emphasizing just how high the current requirements are of accelerating an electric motor.

How would you start a 'heavy' electric motor these days?
From what I have read, inverter drives only control the speed of 'small' electric motors.


Old style circuits like you describe have no feedback from the rotor, you just horse current through the windings to get the rotor to align to the stator's magnetic flux (assuming we're talking about synchronous motors). However, these days what's used is an accurate position sensor (most commonly a resolver) that means from the word go you can put current exactly where it's needed to produce torque (the quadrature axis relative to the rotor flux, if you want to get really nerdy). So basically, for the same current, you get the same amount of torque, regardless of speed (Until you reach speeds where rotor Back-EMF exceeds bus voltage, and field-weakening current is required).

Motors are also mad efficient when you compare energy in to energy out. An engine gets its energy from the fuel, which has a 'calorific' content of energy, which on a good day would probably turn 40% of that energy to kinetic energy. The rest is converted to heat and noise. An electric motor and inverter will have a combined efficiency of circa 95% of the energy from the battery being turned into kinetic, the remaining 5% of the energy being turned into heat. The inefficient part of electric vehicles though is getting the energy into the battery in the first place...
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Easy-X
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PostPosted: 23:47 - 08 Jul 2020    Post subject: Reply with quote

Campbell SOUP wrote:
stuff


Hooray for sanity Thumbs Up
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Coby
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PostPosted: 11:08 - 09 Jul 2020    Post subject: Reply with quote

So Campball;

Are you claiming that there is no longer any need for 'C' or 'D' type circuit breakers?
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Coby
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PostPosted: 12:03 - 09 Jul 2020    Post subject: Reply with quote

Perhaps not.


Ok, 'E' vehicles are still left with two basic problems then:

(i) - The initiation and acceleration of a rotating electric motor.
(ii) - The initiation and acceleration of the rotating drive wheel(s).

Both of the above will inevitably require more energy than for their rotation, once each is up to its' required rpm!
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Campbell SOUP
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PostPosted: 13:07 - 09 Jul 2020    Post subject: Reply with quote

Coby wrote:
Perhaps not.


Ok, 'E' vehicles are still left with two basic problems then:

(i) - The initiation and acceleration of a rotating electric motor.
(ii) - The initiation and acceleration of the rotating drive wheel(s).

Both of the above will inevitably require more energy than for their rotation, once each is up to its' required rpm!


Why? I've just told you that because of rotational position feedback from the rotor allows the inverter to place current directly where needed, the amount of torque output per unit of current used is equal regardless of rotor speed.

So if we're deriving force as a function of Current (remembering that efficiency comes from using more current than required), and force is directly correlated to the amount of current being used, then there is no inefficiency attributed to running at lower speeds.

The Triumph TE-1 isn't going to have an ABB drive strapped to the side of it. You're living in the past, possibly you've even missed the fact that variable speed drives exist now for industrial purposes. We're not tied to the 50Hz mains frequency and haven't been for a really long time. Especially seeing as electric vehicles are supplied DC current from the battery.
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Coby
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PostPosted: 07:03 - 10 Jul 2020    Post subject: Reply with quote

Ok, here's fun:

Can you come up with some prospective current consumption figures for six different gear ratios @ six increasing voltages?


By the way:
You didn't mention whether or not 'C' & 'D' Type circuit breakers are now redundant!
You are starting the motor under load remember.

"Efficiency comes from 'more' current being used than is required"? It's current usage that's killing the batteries!
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Campbell SOUP
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PostPosted: 17:33 - 10 Jul 2020    Post subject: Reply with quote

Coby wrote:
Ok, here's fun:

Can you come up with some prospective current consumption figures for six different gear ratios @ six increasing voltages?


By the way:
You didn't mention whether or not 'C' & 'D' Type circuit breakers are now redundant!
You are starting the motor under load remember.

"Efficiency comes from 'more' current being used than is required"? It's current usage that's killing the batteries!


Apologies, that was meant to read 'inefficiency'.

But yes, there are no circuit breakers required because current is controlled using PWM (Pulse Width Modulation) which allows accurate control of current, and not just basically shorting the circuit. Again, you're thinking in AC supplied fixed speed drives, this side of the millennium we use DC supplied inverters.

(And yes you still get AC supplied 3-phase variable speed drives, but actually inside they turn AC into DC then back to AC again!)

Obviously 'current consumption' depends on a few things, like the individual motor's efficiency, the inverter's efficiency and the operating voltage of the DC bus. (You pointed out earlier that P=IV, so you do the math for what happens when you want the same power at different voltages). But (depending on operating speed & load) you can expect 95% of the power output from the battery to come out the output shaft as kinetic energy, plus maybe other transmission loss (chain etc.).
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Pete.
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PostPosted: 18:10 - 10 Jul 2020    Post subject: Reply with quote

Brushless DC motors are nothing new. I was winding prototypes in the 1980's.
Inverter drives aren't new either, and if you think they are only available for small motors then you're sadly mis-informed.

Star-delta is old hat. EV motors are DC and powered by drives with very complex algorithms.
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1198
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PostPosted: 18:43 - 10 Jul 2020    Post subject: Reply with quote

Pete. wrote:
.... EV motors are DC and powered by drives with very complex algorithms....


What they really need instead is a seven speed gearbox, much like a Cagiva Mito used as a highly tuned two stroke with a narrow band of useable power...
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Easy-X
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PostPosted: 23:39 - 10 Jul 2020    Post subject: Reply with quote

2-strokes cars... keep thinking of the fact the transmissions needed a freewheel or was that just the Trabant?
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Campbell SOUP
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PostPosted: 11:54 - 11 Jul 2020    Post subject: Reply with quote

1198 wrote:
Pete. wrote:
.... EV motors are DC and powered by drives with very complex algorithms....


What they really need instead is a seven speed gearbox, much like a Cagiva Mito used as a highly tuned two stroke with a narrow band of useable power...


Here's a cool chart from the boys at McLaren:

https://1036981-static-assets-mat-production.s3.amazonaws.com/media/images/products/section/e-motor_powercurve.jpg

Image source

The solid red line in the chart shows the maximum power that the motor can output at each speed range. For racing purposes, you want the horizontal part of that line to be across as much of the speed range as possible, as power can always be translated into torque via the use of a gearbox. It's one of the really great things about e-motors, there's no narrow usable band of power, it's actually much wider than that of an IC engine, which negates the need for multiple gears.

Easy-X wrote:
2-strokes cars... keep thinking of the fact the transmissions needed a freewheel or was that just the Trabant?


I think the Trabant needed it because when off throttle you're basically not putting any 2T oil into the engine, which would cause it to seize. I had the pleasure of driving one in Berlin last year, I really hope to own one one day Very Happy
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Pete.
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PostPosted: 16:22 - 11 Jul 2020    Post subject: Reply with quote

Campbell SOUP wrote:

For racing purposes, you want the horizontal part of that line to be across as much of the speed range as possible, as power can always be translated into torque via the use of a gearbox.


Err, no. torque can be multiplied by use of a gearbox. Power is derived from the application of a certain torque and the time that it is applied over.
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