Brushless controller tuning modifications

[Hyena]

Thanks for the info Mr Kang.
I'm aware of the other hobbycity ones. It was more those smart guard ones with the large % remaining display that I was interested in. I'm building a few bikes for friends who need a simple fuel gauge type display and though this would be a good option. If only it measured current as well and displayed used ah instead of just voltage drop it'd be ideal.

Mike, cutting and shutting certainly isn't beyond me! Those devices would be a good option too because you could remove the back of it, mod the resistors and add a heat sink and then mount the top half of the case in a hole in your battery box. I really barely need a balancer though. Aside from the one weak pack I posted about in the turnigy thread (the one that got wet) all the other packs have a max delta v of 0.01v after a full charge, and this is after 100+ cycles with no balancing.

[MrKang]

This sundaynight i had the time to replace the new Fet's from method into the old 48V controller.
I was happy when i grabbed my old dusty Hakko 484 desolder buddy which was all dusted away in a far away corner.
Turned it on ..and ...brrr...brrr...sucked like a little pigplet. So first unscrewed all fet's which were mounted on the coolingplate.
Than piece by piece desoldered all Fet's and all the wires which are used to connect the hub-motor.
Screwed the new Fet's first on the coolingplate , not to tight, and then put it all back into the holes of the pcb.
Soldered them tightly and fresh with some new solder..hmmm...love the smell of it !..hehehe

After that i replaced the 3 caps with 2 new ones. 1000uf/100V. Put a JST Female connector on the data line for programming this sucker later.
Only have to place the two resistors back for 5W types (330E & 680E) so it is functional with 100V.

I hope my wires & plugs are coming this week from hobbyking. i see that they left at 5 and 7 nov. so...maybe i'm gonna finish it next weekend.

Here some pics:

[MrKang]

My goal is to go to work on my E-Scooter instead of driving 1.5 hours in traffic jams. Here in the netherlands we have many heavy traffic jams arround 8am.
The distance i have to drive is arround 50km (google route). I want to capture the route wth a small camera on the front of the scooter. together with a gps tracker and the info from my cycle analyst and the log from the cellogs (4 pieces, each logger on a lipopack) i want to make a complete video screen with all data.

I have been experimenting first with exporting a gpx file into google earth which i can playback..and then i bumped on the first problem.
If it playes back the gpx it isn't shown realtime. So i was trying to change some options and parameters but that ended up with no succes.

After googling my problem i ended up with a 3rd party software app. which imports a gpx file and then uses google earth as a player !

Super !!! see here: http://www.hybridgeotools.com/

So..after figuring that out it was time to test it out. On a normal working day i used the car and recorded the route with gps and camera mounted on my rearview mirror. Then at work i imported the gpx file and used a little program called "Frapps" to capture my screen. I played the gpx file and saw in realtime the exact route on google earth. With the movie that was created in Frapps i also used the amera movie and then combined them with a video program editor. I normaly use adobe after effects. The total output was super !

Next step is to record all 4 lipo packs with the cellogs and use the data to move some meters and implementing that into the video.

The dashboard of my scooter will be modified into a brand new customized dash with 4 cellogs and the CA display and the lights from the turning signals.

All my stuff from hobbyking are at customs!! so i still have nothing received..still waiting for 16Lipo's 50 meters of wire and extensions and a variety of plugs and connectors. Hope they will come this week....

[MrKang]

finally my 1st package arrive out of custom inspection.. it stayed there about 12 days after leaving china with EMS.
Next time i won't spend the extra bucks for EMS shipping because it finally ends up in hold off at custom inspections here in the netherlands.
first i received a letter where to put in a invoice of the parts i ordered with the value of it. Then after 7 days they finally released it. I had to pay 27 euro's !! and 17 of it was for custom decleration administrations...That's a brand new 5000mA Lipo dudes !! i was thinking..

When i opened the box i was wondering if all lipo's are ok.



After testing them all they were all healthy !! ahhh...that puts a load of my mind..

Now i have to wait for the other 3 Batches which also are at customs on 5th november....still waiting !!!!

[MrKang]

speaking of the devil!
BATCH 2 is in da house! and together with a custom decleration i have to fill in for batch nr.3...damnit...



TWO2GO!

[vanilla ice]

Awesome dude, new toys. Even says "toy parts" on the box eh! Suck about the customs fees tho. Are you going to run these in parallel with the low C lipo?

[MrKang]

Are you going to run these in parallel with the low C lipo?

I'm gonna make a whole new setup with these 5A lipo's. I order 12 pieces of 6S and 4 of 4S. Together a want to create a 22S4P config.
I also want to create some new neat packs. I want to make a upper plastic cover which lays on top of 1 lipo pack.(4 pcs 22S1P -> 22S4P)
In that cover i will put in all the balance and output wires. So i finally have one neat pack with the outpu terminals and one balance connector.
I'm going to the 'do it yourself' store to find some good materials to work on that. i will show you the pic's when i find it.

I was hoping to make all the wires this weekend but they are in the other two batches i still have to receive.. i only have some lipo's and some 4mm connectors.

All my celllogs did arrived so i ca modify those first for putting in my dash. I plan to make a total new dash and cover it over the old one. This dash will have
4 cell logs and the cycle analyst display. So i finally have a nice futuristic looking dash with all that displays! yeahhh!

[MrKang]

So i was browing this morning for some parts to make the lipo packs ad i found my stuff !

These are the ones for 4 lipo's !



and this one will be the top where all wires come in and are paralleled inside of it. On that i will place the neg. and pos. with 8M bolts and a final balancing wire.


So journey accomplished !

[MrKang]

I have organized my Lipo Balancers on my shelf to get some room for putting the lipo packs on it when charging.
Yesterday i received my 200W 6S charger from hobbyking with usb port. I installed the monitor software and hooked it on.
Like the graphs that shows all processes.

[MrKang]

pfff.. those cell logs are difficult to order neatly. i have a couple of ideas how to place them in my dash but i only have room for 160mm x 90mm

So i came up with this sollution so it will fit porpperly.





and then total 4 of them in a row. all the sens wires will be in one cable with pcb fuses for safety.
all negative connections will be switched sepperatly by a relais so they only work on powering up the scooter.

[MrKang]

This is my setup for my screen i want to create when i gonna do a test ride on my scooter.



and a piece of video...it's just a test setup i drove with my car...but' it's the idea that counts..

[Hyena]

Cool! Did you make that software ?

[MrKang]

Cool! Did you make that software ?

these video's are all captures from windows applications.
e.g. upper info is captured with "super screen recorder" i just played my gpx file with a program "Active GPX" and then captured only the info dash.
google images were captured with "fraps99" also used active gpx to play the GPX which showed in google earth.

the battery info i just made up but want to have it this way when i have all log data.

These captures are all combined in After effects (video edit program which i work with on daily bases)

I only have to make a program which converts the cellog data into those 22 red lines which will show each cell voltage. and then again capture it with software.

[MrKang]

Batch no.3 has arrived !! finally i can do some pre-work this weekend building my lipo packs.


LET THE LIPO'S BE JOINED TOGETHER !!

[MrKang]

i started making my lipo pack this weekend. All parts were arrived and did some shopping for nuts & bolts.







and then 3 more of these packs.

[MrKang]

BATCH FOUR !! and the last one. It's time to build off my 22S4P Lipo pack!

[vanilla ice]

Luckeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee!

[growler]

I love what you are doing here Mr Kang! I have a similar scooter to yours running with greensaver lead acids but with a 2000w motor .I watch your project with great interest.How do you intend to charge the lipos? All together with a power supply or in parallel groups? And what about balancing? Good Luck!

[MrKang]

How do you intend to charge the lipos? All together with a power supply or in parallel groups? And what about balancing? Good Luck!

I charge them seperate with my lipo balance chargers. in total i have 4 lipo packs. and i have 4 chargers with balancing. I charge them with 10A and monitor them with my PC.

This weekend i will finish the other lipo packs.

[MrKang]

The Power Source is Ready to Discharge !!
Upcoming days i will exchange the old controller with the modified 100V controller and give it a spin.
I'll keep you updated.

[MrKang]

Well today i went for a test drive. My top speed was 66km/h which was pretty fast driving on a scooter with windshield.

All batterypacks just fitted nicely in my topcase. On the bottom the wires are connected to some fuses and the CA sensor.
I recorded the CA output with my logger from sparkfun. Made an excelsheet and created an graphictable.

Here are some pics:



The Speed sensor mounted on my front wheel.
The CA Graphicsheet

[MrKang]

This weekend i did a test drive ...it was a cold day..-8 degrees... my fingers were frozen that's why i just road a little round across my area.
I made a test video with my results.

Just have to see how i can embed this ...i placed it on Vimeo...

only have a link..this forum cannot embed it.


http://vimeo.com/8307957

[vanilla ice]

TEACH ME HOW TO DO THIS!! You are the master, flippin awesome yo.

BTW this thread is too coo to be called "Brushless controller tuning modifications" please rename it to something cooler!

[TylerDurden]

EXCELLENT!

[Lyen]

Your battery packs are making my mouth watering! I am going to grab some LiPo batteries too!