First E-bike build, Hub and Non-hub Prototype Platform.

So I have been designing and sourcing parts for my first e-bike build for about 8 months now and I have finally started buying all my parts. When I first set out to build an e-bike I was very frustrated with the lack of centralization and features offered for the DIY community, so I set out to design my own central computer control system and to implement my own designs in power reclamation, drive systems, motor control. The system I was coming up with was going to require a lot of research and experimentation so I decided to build a modular prototype e-bike for my first build. An over view of this contraption can get a little complex... I will be running 6Kw mid-drive that runs through an IPS crank with three chainrings then onto a Nuvinci N171 Developers kit for the rear wheel, for the front I will be using a 2Kw direct drive hub motor. I'm using a Adaptto Max-E controller for the rear and a Mini-E slaved in 2WD mode, also I'm using the integrated Adappto BMS with a 15Ah 23S (2.4vx23Cells =55.2Vdc; 200amp continuous, 400amp phase) Lithium titanate house battery. I'm building two extra 15Ah batteries that can optionally be added with quick releases to extend range or experiment duration. The host for this mess will be a heavily modified Montague frame. I have a 150 page research document (Word) and a 75 page schematic, design, and parts list (also word) so I could put a whole lot here and will over time as the project takes shape. Because of commercial applications and a desire to patent certain parts of this projects some of the subsystems I will be building and displaying I will not go into any detail of the circuitry or construction. Like I said, the parts are all on order and I hope to have this thing up and running in a couple months. Enjoy.

I set up the Nuvinci N171 Developers Kit on an old aluminum Mongoose frame to start working on the shift maps. I threw together a 22.2Vdc battery to power it. The Mongoose frame will later be cut up and used for stock material for modifying the Montague frame that is in route.

I paid a visit to a store called Airline Hydraulic, I have been there once before and found them to be very helpful and accommodating. My mission was to get some grease seals that were missing on a Neugart WPLE unit I have and to check out some of the aluminum extrusion they carry. I had a great conversation with a design engineer who was very helpful and supplied me with the plugs I needed and several feet of standard and heavy duty aluminum extrusion to experiment welding and bonding with. Apparently this aluminum alloy is difficult to weld. Either way I have enough to do my primary reinforcement and plenty extra to make mounting rails on the bike frame. I'm hoping to find a good way to put insulated power rails in the mounting slots so I can power various modules off it, similar to track lighting.

Hopefully things will really pickup with this project by the end of next week.

My motor arrived from Alien Power Systems today. I'm a little annoyed it had a broken sensor wire but not annoyed enough to send it back. It's a 80mm sensored out runner rated at 6Kw & 80Kv; up to 18S I believe. The main shaft of the motor needs to be turned down 1.5mm for it to fit into the reduction gear input. Today I made some, first, attempts at welding the Aluminum. I was told welding this particular alloy is very difficult and to try blazing. Low temperature aluminum welding sticks (aka aluminum braze) are more like solder and the bonds proved too weak for my application. My test piece was rather small but I was able to weld the alloy to its self, to pure aluminum, and to several other alloys. I am using a Miller 211 mig welder with an argon shield and fusing 1/4in and greater material together. I found that the material needs to be extremely clean to get a good bond. Given my lack of experience I may try to bribe one of my co-workers to do the welding on my bike frame when the time comes. I'll post a few photos later.

Not quite sure what you are trying to do, but good luck with it.

Yeah, that aluminum 'brazing' stuff is mostly zinc. Absolutely useless for anything structural, especially anything that undergoes repeated flex and vibration.
Probably have to find a real good TIG welder to do the welding if it is one of those hard to weld alloys.

Most extruded aluminium is from the 6xxx series alloys and is considered to be weldable. The aluminium alloys that are considered to be unweldable will infact appear to weld nicely, the reasons they are considered not suitable for welding is a high susceptibility to cracking in the haz, so find out the grade of the extrusions you have then choose the appropriate filler to ensure the best results are achieved.

I know the alloy type, it is Al 6063-T651. My goal is to take a Montague frame, which has an oval main tube, and weld extruded squares (the rectangle material shown above and cut in half) to either side to increase the lateral support and provide mounting rails; among some other support additions. The welds are not the prettiest but their strong. I have access to a 211amp MIG welder, it seems to have done the job. I know a TIG will make a pretty weld but I plan on grinding them all down and having the whole frame anodized when I'm done anyway.

Snath used some of that extrusion as the backbone to his first friction-drive:

http://endless-sphere.com/forums/viewtopic.php?f=28&t=12810&p=295818#p295818

I work in an interesting shop, that at times operates similar to a collective, and my official job title is Resident Mad Scientist. Its primarily a truck and auto shop and I am in-charge of anything related to Hi-Rail equipment. I rent a space in the back where I have an electrochemistry & robotics lab and I am in the process of building a rapid prototyping lab. I'm the only one here with advanced science degrees and I do a lot of the engineering but my basic fabricating and mechanical skills need some work yet.

Pictures from earlier.

spinningmagnets said:

Snath used some of that extrusion as the backbone to his first friction-drive:

http://endless-sphere.com/forums/viewtopic.php?f=28&t=12810&p=295818#p295818

Click to expand...

I really like the mounting rail system especially for my application so the bike can be torn down and rebuilt easily. As I have mentioned earlier I hope to install insulated power rails inside some of the mounting rails so I can have equipment cases get power right off the rail.

My rear wheel needs to be relaced because the jacknut that did it for me frocked up the threads on some of the nuts. My bike frame should arrive in the next week, I hope it fits in the sand blaster I have here at work. I'm super excited to get all the frame mods done so I can send it out to be stripped and anodized. I'm still not sure if I am going with plain anodized or with a color. I eventually plan on doing a 5 color ELpaint scheme with animation effects. I turned down and threaded my motor shaft to work with my Neugart WPLE 60. I will have to make a new shaft when I upgrade to a WPLE 80.

I came across this in the facebook ES page. I wonder what the discharge rates are on it? I will be running 16S and that pack is either 16 or 15. I would have to implement a second bank with a dual cartridge system and have an onboard charger from bank 1 to bank 2 (or vice versa... the BMS could syphon power from those cells) and I could have a 30min quick charger I could carry that would also act as a power supply for the main bank.

http://egopowerplus.com/products/56v-lithium-ion-4-0-amp-hour-battery

Update: The output was stated to be 224W equating to 4amps. Now the unit stores 224Wh and I think the question really had the office stumped and I may have go to Home Depot and check it out for myself. Ego does not sell large parts like the straight string trimmer upper battery compartment and trigger housing.

It will be nice when I get a 3D printer in house and can make my own quick change battery housings and docks. I really chomping at the bit for this bike frame to get in. My first reduction drive system I will be implementing will be with a Neugart WPLE 60 (1:8), I also plan on getting a WPLE 80(1:8), and I am looking at a small CVT reduction drive that would be more like traditional RC reduction builds. Because of the open prototyping frame all these units will be able to be quickly swapped out for testing different systems.

First batch of batteries came, along with some other parts. I found these great weather sealed cases originally made for cable TV components.

Any progress ?

How did you adapt the RC-Motor to the gear?

Wanted to start the same project.