EbikeE and BMC for Comfort and Range

General Discussion about electric bicycles.

Re: ebikeE Recumbent Testing - it's alive!

Postby docnjoj » Sat Mar 03, 2012 5:55 pm

I have a E-Bikee with a rack just under the seat. It could house your batteries easily and these racks are still sold. Might be an option?
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 5:59 pm

I'll have to look for those. Didn't know they were still available.
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 6:13 pm

Not easy to find, BikeE underseat racks.
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Re: ebikeE Recumbent Testing - it's alive!

Postby docnjoj » Sat Mar 03, 2012 6:44 pm

Here is one that could work. Not cheep though. It seems that Bike-e parts are getting more difficult to find.

http://www.calhouncycle.com/productcart ... roduct=118
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E-bike stable at our house
Bike-e electric front brushed C/L
Steintrike Mad Max full suspension trike rear Xiongda 2 speed motor in testing
Sun USX delta trike 9C front wheel sort of front suspension
Frame of homebuilt trike in shed with Bafang still on it
Agniusm/A123 AMP 20 36 volts on the Steini and old 10ah Ping paralleled with 12 ah Fatpacks on USX
My wife and I ride the trikes
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 6:55 pm

docnjoj wrote:Here is one that could work. Not cheep though. It seems that Bike-e parts are getting more difficult to find.

http://www.calhouncycle.com/productcart ... roduct=118
otherDoc


Thanks for the link. Looks like a good rack. Not sure if it will fit the square beam of the BikeE...
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 8:26 pm

Installed the Big Apple tire and thornproof tube on the front wheel, and moved the thumb throttle to the right between the brake and shifter. Had to leave a gap so the throttle didn't hang up on a protrusion from the shifter. Adjusted and tested the mirror. Removed the temporary batteries so now it is pedal powered. Started making the new battery setup with 2x3 vinyl downspout. Ordered more vet-wrap.

Next need to make a new wiring harness for the batteries in the square tubes configuration.

Nice weather here today, over 70F, and going to be warmer tomorrow. :)

I need to break out the hydraulic crimper and get busy... :)
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 8:59 pm

Bad News

The zippy batteries fit nicely in the 2x3 vinyl downspout pipe... right up to the wiring pcboard where they get a little taller and wedge.

Back to the drawing board... :(
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Re: ebikeE Recumbent Testing - it's alive!

Postby ddk » Sat Mar 03, 2012 9:05 pm

Alan B wrote:Bad News

The zippy batteries fit nicely in the 2x3 vinyl downspout pipe... right up to the wiring pcboard where they get a little taller and wedge.

Back to the drawing board... :(

were you using the small tubing or the large?
just wondering... it seems a clever solution for packaging LiPo sticks.

*edit* I see you were using the smaller down tube.
It's also available in a larger size of about 3x5
Last edited by ddk on Sat Mar 03, 2012 9:10 pm, edited 1 time in total.
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 9:08 pm

They only had one size at Home Depot. It is 2" by 3". What is the other size??
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Re: ebikeE Recumbent Testing - it's alive!

Postby ddk » Sat Mar 03, 2012 9:11 pm

HD would have to special order it but ~3x5
I know it's available
used it on my house in 2003 :lol:
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 9:15 pm

It looks like there is some square stuff, and some 3x4 inch. Unfortunately that's probably too big.

The Turnigy batteries fit nicely in the 2x3. There is almost an inch available for wiring, so lots of room. Unfortunately more batteries are required and that is a problem unless I downsize the pack.
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Re: ebikeE Recumbent Testing - it's alive!

Postby ddk » Sat Mar 03, 2012 9:26 pm

I'll look into the 2x3 for my own use
Not really familiar with your bike but I just wanted to lend you some information.
Staying with the standard sizes is always less expensive


would welding two tubes together be an option for you?
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 10:25 pm

Really need 2x3-1/2" for these Zippy batteries. Just need another bit of space, even a quarter inch would probably do. Several solutions have fallen just shy of adequate space, unfortunately.

Thanks for the info!
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 10:27 pm

I suppose that cutting two tubes and cementing/welding them together could produce a taller channel.

Thanks for the idea. :)
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 10:50 pm

Battery Plan E

My apologies if this feels like a roller coaster ride. So many plan changes!

This may work out better than I had expected. It is a bit more work, but it is coming together better.

So, I'll take the vinyl downspout and slice off about 1/2" so there is a 2x2.5 inch "U" left. Put a layer of 1/4" foam in the bottom, then the batteries, then lay in the wiring. Add another layer of 1/4 inch foam on top. Then take another "U" piece inverted and slide it over the top, or interleave it, whichever works better. Push it down until the batteries are grasped by the foam. Vet-wrap this tube in several places to compress the foam a bit and keep it in compression. This will lock in the batteries, wiring, and make a compact package that is protected on the sides by 2 layers of vinyl downspout material, and on the top and bottom by one layer plus the foam.

To do this I'll probably have to dig out the table saw to rip the plastic. Carefully and Safely.

There is hope for this yet! :)
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sat Mar 03, 2012 11:28 pm



Thanks!

Above is a link that shows using the 2x3 vinyl downspout material to house Bosch fatpacks, and expand the height 3/8" to make them fit properly. They did this by cutting and splicing with PVC cement. very similar to what I need here. :)
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sun Mar 04, 2012 9:05 am

How can Vinyl Downspout material make a useful battery housing?

I received one PM asking about that, so I'm sure others are wondering as well. I need to add some photos, but it is 5am and I'm not going to get out of this warm bed yet, and the best light for photos is hours away. So I'll try to describe it without using the requisite 1,000 words. :)

I have 6S packs from both Turnigy at 5AH and Zippy at 8AH. I could use either for the bikeE but the Zippy require fewer interconnects and as it turns out they fit the downspout tubing better, except they don't quite fit. More details in a moment.

Part of this process is affected by me getting anxious to get this bikeE on the road. Much of my Turnigy pack is tied up on the Mountain bike so I can use the Zippy more easily without disturbing the already working Mountain bike. I have a few loose Turnigy packs, but only 500 watt hours. I have six of the Zippy and they are (a bit less than) 200 watt hours each. My goal is to put six Zippy packs on the bike for now. That will give me 1200 watt hours optimistically so perhaps I will have 900-1000 useable watt hours and give me a 50 mile range riding efficiently. The seatback, rear tail and underseat areas will all be available to carry other things. The batteries will be out of the way.

Spacewise on the bikeE I have 24 inches on top of the main beam, and 30 inches below. So we can take three Zippy 6S 8AH packs which are each seven inches long, and place them end to end on top of the beam and have a pack that is 21 inches long. The other three similarly packaged below the beam. I'm making these packs 24 inches long to allow some room for connections and the HVCLVC pc board.

This works out especially well for me since I'm planning to use 12S, so each of these two "tube packs" can be 6S with three 8AH packs in parallel. If I make them with the output connector being a 4mm dual banana plug (like a Turnigy battery) they will plug into my already made wiring adapters that series the packs and feeds the Deans that came on the controller.

So I will cut the top of the 24" long vinyl downspout tube off making a "U" channel, lay in some foam, lay in the 3 batteries end to end, lay in wiring, more foam, invert another cut U tube down over that and slide it down till the batteries are tightly captured, and tape or vet-wrap the two U's together into a tubular pack 2x3.5x24 inches long. Then these tube battery packs will be mounted above and below the bikeE beams, probably with vetwrap for now.

For charging I'm getting a Hyperion 1420i so I can balance charge the whole pack at once.

Most of the effort to do this is in making the wiring fit into this long packaging.
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sun Mar 04, 2012 1:26 pm

Uploaded 24 new photos to the ebikeE album:

https://picasaweb.google.com/1158081452 ... directlink

Showing the new front tire, removed batteries, new location of thumb throttle, battery fit in 2x3 vinyl downspout pipe, and the wiring harness that I made that won't quite fit in the SE300 case.

Here are a couple of them:

Image

Image
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sun Mar 04, 2012 2:56 pm

Variable height battery tube

Here are a couple photos showing the 2x3 vinyl downspout material being used as a battery holder. One side was cut off (do this carefully), and two U sections used to create a variable size battery tube:

Image

And now with the top U section slid down over the lower section:

Image
Last edited by Alan B on Mon Mar 05, 2012 5:04 pm, edited 1 time in total.
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Sun Mar 04, 2012 6:55 pm

Wiring Harness

The Wiring Harness is taking shape. I decided to make another run to the hardware store to get a tubing flaring tool so I could flare the other end of the crimp sleeves. That way wires from both directions can safely be used in the crimp sleeve. Otherwise the sleeve has an edge toward the wires on one side since they are made for wires all entering from the other flared side.

Hydraulic Crimp Tool

The Hydraulic Crimp Tool is doing a superb job. It takes quite a few strokes to operate it, but the resulting crimp is very solid. I needed to take one apart, so I tried to squeeze it at 90 degrees to get it to release but it did not. Finally had to cut the wire, the crimp would not release. Really solid! You can pull on the wires hard, they don't budge.

It is really nice to not have to struggle to get the wires into the crimp sleeve. With two #10's and one #12 there is enough room to easily get things in, and we are within the design range of this sleeve. It will hold three #10's so it is not quite full, but close.

Photos coming soon!

Back to it!
Last edited by Alan B on Mon Mar 05, 2012 2:05 am, edited 1 time in total.
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Mon Mar 05, 2012 12:35 am

Wiring Harnesses Completed

Image

The two batteries are nearly done. A little finish work with foam and tape to dress the wiring, plus make and install the balance extensions for getting the balance leads out to the charger, seal these tubes up and mount them on the bikeE! :)
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Mon Mar 05, 2012 12:37 am

Here is the business end showing the power leads and the Methods HVCLVC boards:

Image
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Re: ebikeE Recumbent Testing - it's alive!

Postby Alan B » Mon Mar 05, 2012 2:02 am

Hydraulic Crimp Tool

Image

Crimp Sleeve, completed samples above, standard unused sleeve, and modified with flare on both ends:

Image
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Re: ebikeE with Vinyl Tube Battery

Postby Alan B » Tue Mar 06, 2012 1:31 am

Batteries are ready. Made adapter cables for balancing, organized the wiring, attached the HVCLVC boards, and closed up the batteries.

These are ready for mounting on the bikeE.

A storm is coming in tonite, no good riding weather till wednesday. With a bit of effort and luck we'll be ready for a commute test run on Wed or Thur.
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