The Resurrection of Motor #3

General Discussion about electric bicycles.

The Resurrection of Motor #3

Postby Stone Meadow » Fri May 25, 2012 1:09 pm

After much hemming and hawing about which motor to buy...and dithering over how to talk my wife into it...I bought motor #3 off of this for sale ad. The seller promptly shipped it, and the package arrived in good shape 2 days later. (Thanks John! :mrgreen: )

Since it was only 50 bucks for the kit (motor, controller, throttle and harness) I didn't get any guff over the purchase, though I hadn't yet started talking about a battery pack. Then I had a brilliant idea...get my wife to suggest I install it on her bicycle! :lol: To do that I expressed some reservations about putting it on my bike, saying that I was afraid it would make my morning 10 mile ride to work too easy, blah, blah, and she fell right into my trap by volunteering to have it installed on her bike. I wasn't too surprised, since she takes about 20 minutes longer than I do to make the ride and always arrives a bit spent.

So last night we spent a little quality time looking at battery packs. At first she was all like, "Hey, a 48v12ah SLA pack is only $200!" I said, "Yeah, you're right. Of course, those 4 batteries weigh 14 lbs apiece, but I'm sure I can fit that 60 lbs (with pack and rack...$50 more) over the rear wheel of your bike, Honey."

*long silence*

"How much is a LiFePo4 pack?"

"Says here $530 with rack, BMS, charger and locking aluminum quick disconnect battery pack. And it all weighs less than 20 lbs."

*lets fly drift with the current*

"Um, let me think about it overnight."

ZING!!!! :mrgreen:
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Re: The Resurrection of Motor #3

Postby Stone Meadow » Fri May 25, 2012 1:21 pm

So the stage is set. I'm going to let her decide which battery she wants, then buy and install it. There's no big rush, though, since the kit has a couple of issues. As it said in the for sale ad:

Motor 3 - Front 26", I forget if it is Wilderness Energy or Golden Motors. From my very first ebike, a complete 'kit' including throttle, 48v25a controller, and my first attempt at a wiring harnees. This has two serious flaws. First, note that one side of the axle has a spacer intended to rest against the inside of the fork, but this spacer is missing from the other side. Second, note that the phase wires got twisted when the wheel walked out of the forks due to serious flaw #1. For the whole 'kit', $50.


Here are the pics from the ad...
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Motor 3 insert twisted phase IMG_3931.jpg (148.41 KiB) Viewed 222 times
Motor 3 no insert 3932.jpg
Motor 3 no insert 3932.jpg (155.11 KiB) Viewed 222 times
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Re: The Resurrection of Motor #3

Postby Stone Meadow » Fri May 25, 2012 1:28 pm

I'm wasn't really concerned about either of these issues, as I not only have a fairly complete fabrication shop, but I helped my brother-in-law do minor repairs to his ebike harness, as well. Anyway, after work last night I popped the side cover to have a look inside and shoot the hall wires. In spite of the twisted harness all appears to be working fine. Popping the cover also allowed me to take the dimensions of the step washer to turn a new one on the lathe, which I'll do in the next few days. Here are a couple of pics of the naked bits... :lol:
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Re: The Resurrection of Motor #3

Postby Stone Meadow » Fri May 25, 2012 1:33 pm

Quick question about the controller...

I know what the top three plugs are for: battery, control/power leads and throttle at top, but what about the single-lead and two-lead below? Is one of them possibly for an on/off switch? I ask because there is no external switch. Any insight would be appreciated...thanks! :mrgreen:
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Re: The Resurrection of Motor #3

Postby amberwolf » Fri May 25, 2012 2:23 pm

You may have to experiment to find out what they are for--best is to leave them alone if it all works without them. ;) Or you can open up the controller and trace where they go--often the names silkscreened on the PCB next to the pads are descriptive enough to figure out what they are for.

I'd guess the two wire is for ebrake.

The one wire could be to connect to a keyswitch between it and battery positive, but you wouldn't want to try that unless you're sure. ;)
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Re: The Resurrection of Motor #3

Postby Stone Meadow » Fri May 25, 2012 2:31 pm

amberwolf wrote:You may have to experiment to find out what they are for--best is to leave them alone if it all works without them. ;) Or you can open up the controller and trace where they go--often the names silkscreened on the PCB next to the pads are descriptive enough to figure out what they are for.

I'd guess the two wire is for ebrake.

The one wire could be to connect to a keyswitch between it and battery positive, but you wouldn't want to try that unless you're sure. ;)

Good suggestion! I'll take a peak and let you know.
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Re: The Resurrection of Motor #3

Postby oatnet » Fri May 25, 2012 3:13 pm

Stone Meadow wrote:Quick question about the controller...

I know what the top three plugs are for: battery, control/power leads and throttle at top, but what about the single-lead and two-lead below? Is one of them possibly for an on/off switch? I ask because there is no external switch. Any insight would be appreciated...thanks! :mrgreen:


viewtopic.php?f=6&t=848

I see why you were asking now - re-reading the 2007 post from when I used this to build my very first ebike (link above), this was setup so that I could put (4) 7ah SLAs and the controller :oops: :roll: in a bag, that I could easily disconnect and remove it so nobody would steal them. I built a switchbox on the positive side of the battery, and used that to turn main power on-off. I think you are looking for a switchbox that turns the logic side on/off - a lot of controllers do not have a switch, some controllers have a switch built into the case, and some (Kelly) have separate leads for an external switch.

I always put a switch on the power circuit, and never use the logic-side switch. My switchboxes have (2) switches, and I put a pre-charge resistor around the second switch. Throw the first switch, the second switch's resistor lets enough current through to slowly charge the caps, then I throw the second switch, and the system has full current available.

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Re: The Resurrection of Motor #3

Postby Stone Meadow » Fri May 25, 2012 4:26 pm

oatnet wrote:I always put a switch on the power circuit, and never use the logic-side switch. My switchboxes have (2) switches, and I put a pre-charge resistor around the second switch. Throw the first switch, the second switch's resistor lets enough current through to slowly charge the caps, then I throw the second switch, and the system has full current available.

-JD

That makes sense, and I will have to try to come up with something like that. I've ridden just a few ebikes (all either "store bought" or comprehensive, late-model conversion kits) and all had either an external switch on the controller box or a prominently located remote.
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Re: The Resurrection of Motor #3

Postby Stone Meadow » Tue May 29, 2012 11:46 am

I didn't make the time to whittle a new spacer this past weekend, but I did draw it up in CAD. That's half the job, right? :mrgreen:
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shaded spacer.GIF
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wireframe spacer.GIF
wireframe spacer.GIF (11.9 KiB) Viewed 145 times
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Re: The Resurrection of Motor #3

Postby oatnet » Tue May 29, 2012 3:50 pm

Yeah, now you just print it out,right? :P

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Re: The Resurrection of Motor #3

Postby Stone Meadow » Tue May 29, 2012 4:29 pm

oatnet wrote:Yeah, now you just print it out,right? :P

-JD

Would like that in chocolate or strawberry, sir? 8)

Seriously, is there any reason this spacer couldn't be made from aluminum? Steel is such a pita to bore out.
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Re: The Resurrection of Motor #3

Postby amberwolf » Wed May 30, 2012 3:15 am

Stone Meadow wrote:
oatnet wrote:Yeah, now you just print it out,right? :P

-JD

Would like that in chocolate or strawberry, sir? 8)

You can do that, you know:
http://www.evilmadscientist.com/article.php/candyfab
Just add flavoring...
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Re: The Resurrection of Motor #3

Postby Stone Meadow » Wed May 30, 2012 8:34 am

amberwolf wrote:You can do that, you know:
http://www.evilmadscientist.com/article.php/candyfab
Just add flavoring...

Yes I did know that...and figured anyone savvy enough to joke about printing it would know it, too. :mrgreen:
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Re: The Resurrection of Motor #3

Postby ohzee » Wed May 30, 2012 9:40 am

haha yea - I thought that yesterday when it was mentioned - I remember the thread where someone made bike parts via the printer.
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