Hillzofvalp's 29er Thread... now with custom 63T (cromotor)

[Samd]

I like it. What if a solar company gave you a free panel to charge with in exchange for advertising?

[hillzofvalp]

yeah, I'll have to look around for a solar sponsor.. solar fenders would be cool.

So here's a little update. I went ahead and went with a boring shape.. it looks larger than it will be when it has a 1cm transparent edge all the way around. I am hoping that I can shine some leds from inside that will illuminate the edges. Even still, it could've been smaller but I was too lazy to cut off up to 3/4" of the u channel legs. MAybe for a summer project.

all in all I think this will allow me to change battery chemistries fairly easily. Maybe will need shims for certain lipo.. but it will work well to keep them a little bit compressed. Also have an arduino I want to cram in here... and needed a place to mount the balance connector.

Any recommendations for sealing it up? I was thinking some kind of silicone strip... you guys probably know just the ticket




pack won't be shaped like this.. it will be 20s-21s.. this is 14s5p.

[Samd]

I love the colour combo - something about black and tan. Hey wouldnt solar fenders be cool. Perhaps you could put some hinged ~12 inch square photo voltaics on the side of your enclosure and fold them up to be horizontal when you're stopped.... Might get stolen I spose.

For seals? Perhaps - this. I just used this self adhesive window seal strip here to drop my power bill a packet. There are several brands and it seems to be available globally. Most of the local hardware stores here stock it. Available in various gauges and widths. Cheap. And the silicine rubber is nice and soft..
http://www.raven.com.au/domino/raven/RPCEN.nsf/e74577f8ef49017dca256b5a0005e4a8?OpenView&category=Weather%20Strip%20%28Self%20Adhesive%20Foam%20Tapes%29&type=door%20seals

I really like the aluminium mounting method there - you've given me good ideas!

[Samd]

Hey rather than an image what about a great quote relating to ebikes.
http://www.quotegarden.com/bicycling.html
"When I see an adult on a bicycle, I do not despair for the future of the human race." ~H.G. Wells

Maybe Use wordle.net to generate the image, and use a pdf generator such as pdf 995 to make a pdf print-to-file of it. Then give that to your signwriter...

[hillzofvalp]

yeah, I'll have to look around for a solar sponsor.. solar fenders would be cool.

I was thinking of solar fenders, actually. I like the blue a lot too. My rear wheel will be all black with blue nipples... Thinking about spraying the seat post.

If your try this mounting method, only do it on steel bike.

[Samd]

What about a QR code link to this site? That way people can walk past and find out more:
http://qrcode.kaywa.com/img.php?s=12&d=http%3A%2F%2Fwww.endless-sphere.com%2Fforums%2Fviewtopic.php%3Ff%3D3%26t%3D32037

[hillzofvalp]

that's a cool idea. thanks.

It's not hard to print out stuff on my own printer and stitch it together... but walmart does pretty cheap 24x36" pictures (<$15).

[hillzofvalp]

For seals? Perhaps - this. I just used this self adhesive window seal strip here to drop my power bill a packet. There are several brands and it seems to be available globally. Most of the local hardware stores here stock it. Available in various gauges and widths. Cheap. And the silicine rubber is nice and soft..
http://www.raven.com.au/domino/raven/RPCEN.nsf/e74577f8ef49017dca256b5a0005e4a8?OpenView&category=Weather%20Strip%20%28Self%20Adhesive%20Foam%20Tapes%29&type=door%20seals

I really like the aluminium mounting method there - you've given me good ideas!

Used inner tube? I need something thin and reusable

[Samd]

Hi HOZ,
they usually only have adhesive on one side, so if you stick the adhesive side to your aluminium tube,you could reuse them indefintely. or the other way around for that matter.

How is your build going? I keep checking every few days to see if there has been a change!

[hillzofvalp]

Well, I've been waiting on 13-14 spokes for my velocity chukker rim. They guy I originally ordered them from (John Kovachi, a BMX legend) recently passed away. The order was placed over a month ago. I ordered another set from holmes.. which gives me reason to run dual 2807s in the future (with an extra set of spokes sized for 9c)!

I got my calipers used, and the pads are somewhat worn.. I think that is why I'm not getting good braking pressure after installing 203mm rotor and even after re-bleeding lines. So I think those are $15..

Other than that, I routed RFID wires through the frame. I drilles a hole straight through one water bottle screw... then took an hour feeding them through. Intitally I had frocked up the seatpost by drilling a hole at too much of angle.. removing lots of the carbon from the inside. I filled it with epoxy, drilled in the right place... and now I'm machining a 40mm aluminum insert to reinforce the area that may or may not be much weaker.

I'm also trying to obtain a $50-80 arduino with a built in wifi chip, so I can charge my bike in the garage beneath my apartment complex and still monitor the charge. (or monitor it anywhere with 3g for that matter). I plan on running temperature sensors from both the pack and the psu (4x hp esp114). I figure the best security option will be this charger. For example, I can have it post to a web page when it's been unplugged. I obtained a few relays and a 60A cont. contactor as well as a hall effect sensor that works well for more constant, low current measurements less than 50A (it can measure up to 200A though).

On the theft issue, I'll probably also have a lot of big High Voltage symbols as well as a semi-professional looking warning label (with instructions)

So those are things I'm still pondering. I also need to find a good solid box to mount all my esp 114s in.. they are over 130mm square and probably 2.5x that long each. They would be pretty sheltered from the weather (open air parking garage), but I'd like to add elements of security and safety, while not getting too expensive. I am after all leaving this thing parked in the corner of a public parking garage. There are things I can chain it to, and I have a parking permit so my landlord doesn't care.

I also am wondering if I should use a 4-channel digital pot to alter the voltages on each supply as a unit, so they are all sharing equal loads. I don't really understand yet exactly what I need to do with arduino to accomplish what I want with a CC-CV psu bank.. I'll certainly have a funciton that determines the interval at which the resting voltage is checked, but I may just do it manually and find out a charging current at which it is almost charged... and trip the contactor then. Though I wonder how much I need to get accustomed to winter weather, and whether this will effect my charging program as well as the operation of the psus themselves.

The other thing is I haven't decided whether I should have an isolated battery to power the arduino in the psu. This way I could have a separate relay that triggers the AC off after it disconnects pack contactor. I'm unsure what kind of load this circuit sees, but hopefully it's on it's own auxiliary power circuit and it is okay seeing 12-20A. If I tripped it it would be a pain. might ask landlord.

If I get a Mega arduino board, I may have enough pins to read individual cell voltages and post those to the web page as well.. But this is all functionality that is likely at least a few months out.

Currently need to get it running! Give me spokes! How's that for an update?

[Lemlux]

Back to your ideas about selling advertising space and going solar. You could get one of these Extrawheel Advert trailers and tow paying advertisements some of the time and solar panels the rest of the time.

http://www.biketrailershop.com/extrawhe ... hwodqjKaNw

[hillzofvalp]

HAha I would never pay $300 for that. I could make that without even welding for much less: 8020 aluminum extrusion.. and be able to repurpose it later on.

GOOD IDEA though. Every beginning and end of semester, the bookstores run around campus pulling huge advertisements on trailers.. for buying back students books etc. I will have to speak with their manager sometime.. I could definitely get more looks than a pickup and trailer~--! I can go right in the heart of campus.


RE: wifi charger monitor:

I found some code online that does not require hosting a webpage.. Rather, I can now simply gather the data on the arduino and have it upload it to twitter every so often. (hopefully at least every 30 seconds. Just have to make sure the netowrking code doesn't cause a hang up towards the end up the charging cycle... I wouldn't want to have a network problem and an overcharged battery pack. On second thought I'll probably include fewer updates towards the end of the charge... I may be able to figure out through experimentation just how long is left before charging completes and output this (then I could stop uploading to twitter say 5-10 minutes before end of charge cycle and wait till end of charging).

[hillzofvalp]

Finally got some spokes (thanks, holmes, for being quick).. have everything at the bike shop ready to build when I have the time. I just made final grinds to aluminum enclosure and tapped all the mounting holes (30 of them).. Looking sweet, just need to find a place on campus that will allow me to do some big prints for free...

Already thinking about a belt RC drive and I haven't even used my 9c more than 100 miles.

This picture turned out cooler than expected.




On the charging front, I picked up some scrap 80/20 aluminum from work to enclose 4 hp esp114 power supplies. I am getting a 25A draw at 50% SOC, so I wonder if it would reasonable to set LVC low enough to get reasonable capacity from pack but high enough that it doesn't blow the breaker. I may be able to get away without using a current modded meanwell, but just a microcontroller cut off (based on charging current and safety timer).

It'll be a pretty huge supply (26"x8"x11"), but it will allow me to grow with it (80/20 is easily reconfigurable)

[grindz145]

Sweet lightcycle shot:)

[edcastrovalley]

What's your favorite sports team? I've alway liked this one. How cool would that be on your e-bike?

[hillzofvalp]

very.. though the only sports team I can appreciate these days is Purdue. Maybe a take on this:

[hillzofvalp]

Finished wheel today. Got it up to 20-25 units on the park tools tension meter.. We will see this weekend if any spokes get broken!\

[hillzofvalp]

It's done. At least the GIST of it. Need to polish everything off to make it look like a finished product (decals/light mounting/security/rfid, etc.). I LOVE IT. Well balanced. 2.35" Big apples.. Reba fork at 160psi. Hauls ass up hill. Much faster than it was when I had thrown everything on a rack.

Rear wheel build to velocity chukker rim on first ride was stiff. No annoying sounds.. I have the spoke tension at like 95-110 units (whatever they are).. or 19-25 on the park tools meter. Probably unnecessary with this stiffer rim.. but hopefully I don't need to true it very much.

Some of the EV guys on campus like how it turned out. I let my friend ride it and he said he would easily ride this instead of a car.

Next project is to augment the pack from 14 to 20S and move the controller outboard for cooling... maybe even try a matching 2807 front wheel for 2WD. I was thinking about doing some programming to have traction control and to prevent motors from fighting each other. This could be done by comparing the rpm of each wheel and have controller adjust throttles independently

[ashwright]

Next project is to augment the pack from 14 to 20S and move the controller outboard for cooling... maybe even try a matching 2807 front wheel for 2WD. I was thinking about doing some programming to have traction control and to prevent motors from fighting each other. This could be done by comparing the rpm of each wheel and have controller adjust throttles independently

If both wheels are on the ground, wont they always be spinning at the same speed. Otherwise the front of the bike would run further away from the rear.

[hillzofvalp]

when accelerating the front wheel will spin more and skid if they each receive same throttle. Wait shifts to rear.

[Samd]

Awesome! Nice to thinkof next steps, but I am sure it's great just to enjoy!

[Hillhater]

.. maybe even try a matching 2807 front wheel for 2WD. I was thinking about doing some programming to have traction control and to prevent motors from fighting each other.

you are over thinking & over complicating it.
The motors wont "fight" each other, all they will do is drive or slip if there is not enough grip, just like a single wheel drive...and few see the need for traction control on those !
...of course, both wheels "slipping" as on ice could be interesting ..but that is what the throttle is for !

[hillzofvalp]

Not really over complicating it. Other forum. Members report having to tune down the front hub for a ratio of 30-70.. And yeah having it work this way winout variable throttle asjustments would cause more spin out and more likely crash. If one motor is over working all the time there Is also an efficiency loss

[hillzofvalp]

I have now covered the windings and lam edges with epoxy to hopefully solve the short issue. In the process of removing the nut to take motor covers off, I rubbed off some of the insulation on the sensor harness, which I believe shorted one hall. So I have one replacement hall on the way, cause I can't find my spares... If you use magnet wire for hall sensor wires, make sure there isn't a huge jut in the splice between the 12 gauge deans (in my case) and the cheaper wire from axle to motor. got to be able to clear the axle and washer over the joint.

Also just received 35 more A123 cells for 20s5p or 21s5p. I would like to hear your advice in regards to whether or not I should cycle the new cells twenty times before supplementing my current pack which has minor use. I suppose cycling them is the best option, though only ~.22% of their expected 10-12% life diminishment over 1000 cycles has been achieved. (11-15% decrease over 1000 cycles multiplied by 20/1000). I don't know the realistic cell-gap that will develop, and I rather not have to balance them all the time cause I only have 14S with my hyperion..

Adding more cells will require moving the controller out of the enclosure. I haven't decided whether it will be mounted on the downtube or rear rack, and have not figured out how to weather proof the controller.

[valsislav]

Nice build!
I love the superthin triangle storage - and the design simplicity is beautiful.
I also like that you can change your graphics as desired under the acrylic.
2thumbsup!