Electric Dirtbike 15 KW

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Dopplercana
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Electric Dirtbike 15 KW

Post by Dopplercana » Dec 30, 2014 8:58 am

I would you to introduce my project :
Integrate an electric motor into a gear box.

Specifications :
The motor is an Alien Power System 12090 Outrunner brushless motor 130KV 15 000 W
The EV : Alien 7Kw 48-60V EV controller-CA direct plug
DSC_1115.JPG
The motor come into the gear box. The motor drives the clutch and the gearbox. I keep the 5-speed for greater speed range.
DSC_1110.JPG
DSC_1108.JPG
The motor attached to the support.
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DSC_1137.JPG
Realization of a box for batteries :
6 x ZIPPY Flightmax 8000mAh 5S1P 30C
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DSC_0666.JPG (211.08 KiB) Viewed 453 times
The bike is charging after a ride in the snow =)
DSC_1225.JPG
A video is coming...................

Dopplercana
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Re: Electric Dirtbike 15 KW

Post by Dopplercana » Dec 30, 2014 2:42 pm

The sound of the motor in neutral position:

https://www.youtube.com/watch?v=DpgnZjq ... e=youtu.be

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Re: Electric Dirtbike 15 KW

Post by Dauntless » Dec 31, 2014 1:16 am

I'm dying to hear you say that motor holds up under serious dirtbiking.

Did you hollow out the original engine or is that a new housing?
Any sufficiently advanced technology is INDISTINGUISHABLE FROM MAGIC!
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gogo
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Re: Electric Dirtbike 15 KW

Post by gogo » Dec 31, 2014 10:42 am

Does that motor have sufficient back iron to prevent eddy currents from heating the aluminum engine case surrounding it?

[EDIT] I seem to recall someone having problems with the heating of surrounding stationary metal in a similar setup and mentioning that those type of motors are usually mounted in the air without anything near them, so the motor designers don't need to spec to prevent flux leakage.
Subject: Electric Surf Board
blisspacket wrote:I had a bright U of Fl student point out to me that surrounding an outrunner motor with aluminum is a no-no. I don't know if yours might be set up that way. There are magnetic influences within the outrunner which get messed up when contained within aluminum. The practical test to illustrate this: drop a neodymium magnet through an aluminum tube. You'll observe that there seems to be less gravity within the tube, and the magnet drops markedly slower than just letting it go in free air. :?:
Also: Subject: Newbie from Norway building JR e-trials bike.
Last edited by gogo on Jan 01, 2015 10:39 am, edited 2 times in total.
"A conclusion is the place where you got tired of thinking." -Steven Wright

Dopplercana
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Re: Electric Dirtbike 15 KW

Post by Dopplercana » Jan 01, 2015 7:07 am

Dauntless wrote:I'm dying to hear you say that motor holds up under serious dirtbiking.

Did you hollow out the original engine or is that a new housing?

The base engine is from a 450 CRF 2003.
The left housing was milled in order to integrate the electric motor.

Below the housing concerned:
IMG-20130321-01080.jpg
IMG-20130321-01080.jpg (233.82 KiB) Viewed 446 times
IMG-20130321-01079.jpg
IMG-20130321-01079.jpg (232.19 KiB) Viewed 446 times

Dopplercana
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Re: Electric Dirtbike 15 KW

Post by Dopplercana » Jan 03, 2015 10:08 am

gogo wrote:Does that motor have sufficient back iron to prevent eddy currents from heating the aluminum engine case surrounding it?

[EDIT] I seem to recall someone having problems with the heating of surrounding stationary metal in a similar setup and mentioning that those type of motors are usually mounted in the air without anything near them, so the motor designers don't need to spec to prevent flux leakage.
Subject: Electric Surf Board
blisspacket wrote:I had a bright U of Fl student point out to me that surrounding an outrunner motor with aluminum is a no-no. I don't know if yours might be set up that way. There are magnetic influences within the outrunner which get messed up when contained within aluminum. The practical test to illustrate this: drop a neodymium magnet through an aluminum tube. You'll observe that there seems to be less gravity within the tube, and the magnet drops markedly slower than just letting it go in free air. :?:
Also: Subject: Newbie from Norway building JR e-trials bike.

I had not thought of this.
But how to do the difference between normal heat of the electric motor (about 10% ) and heat due from eddy current?

What I see:

When I ride a long time, the engine mount (part milled) is about 50 to 60 °C but the gear box is not hot.

This is an interesting observation.

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gogo
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Re: Electric Dirtbike 15 KW

Post by gogo » Jan 03, 2015 10:14 am

Someone suggested running the motor without load while its installed, and then 'open -air', and measure the current difference. While you have the motor 'open-air' you can hang a paperclip on a string and hold it close to see if there's 'some or none' flux present.
"A conclusion is the place where you got tired of thinking." -Steven Wright

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Re: Electric Dirtbike 15 KW

Post by querlenker » Apr 13, 2015 2:48 am

Any news about this nice project?

Kin
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Re: Electric Dirtbike 15 KW

Post by Kin » Apr 14, 2015 2:22 pm

gogo wrote:Someone suggested running the motor without load while its installed, and then 'open -air', and measure the current difference. While you have the motor 'open-air' you can hang a paperclip on a string and hold it close to see if there's 'some or none' flux present.

Might be easier to measure leakage by just measuring the open air vs. mounted current draw for a given speed. So long as you don't have differences in your open air mount and your mounted mount, then the current increase from mounted should be a consequence of the flux losses heating surrounding material.
New to endless-sphere? Notice a lot of signatures recommending Ebikes.ca? That's because it's the best place for a quality and manageable, (but still 'real'), first build. Justin is a solid supporter of electric bike development, and a good source of equipment.

Dopplercana
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Re: Electric Dirtbike 15 KW

Post by Dopplercana » May 10, 2015 6:32 am

querlenker wrote:Any news about this nice project?
P10200861.JPG
My Dirtbike in action :

Last edited by Dopplercana on May 11, 2015 4:08 pm, edited 5 times in total.

Animalector
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Re: Electric Dirtbike 15 KW

Post by Animalector » May 10, 2015 6:54 am

And... AWESOME!!!!!!

well done

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Re: Electric Dirtbike 15 KW

Post by granolaboy » May 11, 2015 1:30 pm

man, that thing RIPS! Awesome is right!
2010 EVT 168 @ 69v

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livetek
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Re: Electric Dirtbike 15 KW

Post by livetek » May 21, 2015 2:07 pm

Awesome !! That's a monster !
Can you make more vids ? Thanks ! :)

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louis raaijmakers
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Re: Electric Dirtbike 15 KW

Post by louis raaijmakers » Jun 25, 2015 8:56 am

hi,
nice project you made here!
i am also planing of doing this but then with a streek kart and an brushed motor and a 48v 300a controller.
do you need al gears? and what do you recomend a gearbox from a 150cc moped? or do i need to look in 500cc gearboxes?

greetings louis

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Re: Electric Dirtbike 15 KW

Post by jase1979 » Jul 06, 2015 9:42 am

What make / brand is the original bike? Great build.

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Re: Electric Dirtbike 15 KW

Post by Ykick » Jul 06, 2015 11:48 am

Nicely done! Thanks for sharing your good work.
Talent must not be wasted.... Those who have talent must hug it, embrace it, nurture it and share it lest it be taken away from you as fast as it was loaned to you.

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Dopplercana
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Re: Electric Dirtbike 15 KW

Post by Dopplercana » Jul 13, 2015 6:48 am

livetek wrote:Awesome !! That's a monster !
Can you make more vids ? Thanks ! :)

Thanks,
I'll try to make a new video this summer.
I saw that you live in France. Where exactly ?
I come from the 68 .

Dopplercana
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Re: Electric Dirtbike 15 KW

Post by Dopplercana » Jul 13, 2015 7:02 am

louis raaijmakers wrote:hi,
nice project you made here!
i am also planing of doing this but then with a streek kart and an brushed motor and a 48v 300a controller.
do you need al gears? and what do you recomend a gearbox from a 150cc moped? or do i need to look in 500cc gearboxes?

greetings louis
Hi,
Yes I need all the gears, I hold the engine speed to have the nominal power.
It's hard to say without additional elements. What is the size of the engine?
I use a gearbox from a Honda 450 CRF.

Dopplercana
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Re: Electric Dirtbike 15 KW

Post by Dopplercana » Jul 13, 2015 7:18 am

jase1979 wrote:What make / brand is the original bike? Great build.

The gearbox comes from a Honda 450 crf. The rest is an assembly of dirt bike parts.

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Re: Electric Dirtbike 15 KW

Post by livetek » Jul 13, 2015 7:20 am

I've sent you a PM :wink:

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Re: Electric Dirtbike 15 KW

Post by jase1979 » Jul 13, 2015 8:48 am

It's a small bike though. I don't know much about dirt bikes. Is its like a pit bike or a kids motorcross like a kx80? Cheers

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Re: Electric Dirtbike 15 KW

Post by Dopplercana » Nov 20, 2015 4:43 pm

jase1979 wrote:It's a small bike though. I don't know much about dirt bikes. Is its like a pit bike or a kids motorcross like a kx80? Cheers
Exactly it's like a Pit bike.
Below the site where I bought a few items:
http://www.newmotorz.com/dirt-bike-pit-bike.html

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Re: Electric Dirtbike 15 KW

Post by Dauntless » Nov 20, 2015 7:56 pm

How IS the motor doing? Anyone have a mileage to hope for it holding up?
Any sufficiently advanced technology is INDISTINGUISHABLE FROM MAGIC!
- Arthur C. Clarke

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Re: Electric Dirtbike 15 KW

Post by Dopplercana » Nov 21, 2015 6:37 am

Dauntless wrote:How IS the motor doing? Anyone have a mileage to hope for it holding up?
The motor works well, I use a ventilator to cooling, the temperature remains acceptable into the gearbox approx. 60 - 80 °C (it depends on the outside temperature).

I made twenty loads and for the moment no problem (no wear, no play).

hoping to have answered the questions...

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Re: Electric Dirtbike 15 KW

Post by Dopplercana » Nov 21, 2015 6:41 am

Some specifications that I had not communicated :

Weight : approx. 70 kg
Power peak : 15 kW (20 ch)
Couple motor : approx. 20 N.m / couple max (1th gear) : 320 N.m
V max : 75 km/h
Battery : 55.5 V / 16 A.h
Gearbox : 5 gears
Autonomy : 45 - 60 minutes
Charging time : 3 hours

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