my inrunner build ? go ahead and laugh

[etard]

It just amazes me the fabrication and precision you guys get with regular laymen tools. It inspires me to try the same thing with the jumbo sprockets. I like the use of an alternator case, I might have to scour the pick a part and do the same.

[enoob]

It just amazes me the fabrication and precision you guys get with regular laymen tools. It inspires me to try the same thing with the jumbo sprockets. I like the use of an alternator case, I might have to scour the pick a part and do the same.

indeed. and thank your for the compliment . any help i can be just let me know, id love to start a little payback for what ive got from here in ES already. you may still wanna wait to see whather or not im wasting my time or not yet but so far its been fun AND i just did the math . even after getting the auto repair shop to do the rewind @ $50 im still easy under $100 so im gonna go get brand new spakedy bearings for this thing , a whopping $12 canadian and that will put me over 100 by 3.80 . got the alternator for free so that helped , when your out looking for one id suggest telling them you want one thats NFG already . and use that term . in slavage yards NFG is well known as No F#%*king Good. it will help you get a low price.

Now with that said i will tell you ive been cutting and shaping material for the better part of 25 years . lots of little things can and will affect the outcome of your time spent. best advice i can give is ask questions when your going to do something you haven't tried yet . i still do .this place is a great start.
i should warn you that quite often to build something the cost of tools if you dont have them already will almost always cost more than just purchasing existing product. Of course the up side is if you take the DIY route and commit to buying the tools you CAN often make repeat copys and turn an expense into a possible break even or better. With the added bonus of knowing who to talk to for replacement parts at cost

for what ive done so far a guy would need at least a small benchtop drill press and a hydralic press and the simple hand tools youve seen (the air tools and grinder ive used could be done with a chainsaw file and flat bastard file , just take longer and give you bigger arms) . gimmie a bit and ill edit in some photos of the diy press i got with a 10ton jack , complete getto but its done alot of work for what it is. cost is the same as it would take you to get an alternator shaft re&re'd at a shop. and again your left with the ability to rebuild a roasted motor.

here we go . this is just the stuff in the garage here at home so i figured these would be good to share . the grinder dolly on wheels i had to chuck in . for anyone working in a tight space this is a great little bit to have. i can wheel it outside when i dont want to make a mess inside and the grinder comes off with 2 bolts making it a nice little trolly for small jobs around the house.



that aluminium dust and shavings get everywhere and unlike the wood dust im used to are a pain to clean . that fresh pile you see behind the press is from what ive started today . will share soon

[AussieJester]

Now with that said i will tell you ive been cutting and shaping material for the better part of 25 years .

^^^ Something money can't buy chaps...time & SKILL.. Thankfully for the rest of us mortals there is CNC LoL

KiM

[enoob]

sorry johnrobholmes missed you on that last one. ty for the compliments .
the lean towards sensored controller is coming from my (admittedly limited) observation that sensored seems to be holding up to ebike application better. my guess is the rc stuff , since optimized for weight and size, is having trouble dealing with sync issues that their purpose built use would otherwise not subject them to.

and AussieJ i take that with pride coming from someone that can produce what you do. cnc milling machine would be fun to have but it will kind of be like a junkie having a machine around that gets high for ya, it'll be missing something.

[enoob]

well i figured while im in a holding pattern waiting on a suitable controller or more magnets i may as well keep busy . and since i intend on making more than one of these and sending one to thud. (still not kidding ) i took steps to make that happen . got a few more alternators and now i am officially on holidays till the new year so here i come.

so now it comes down to what gets here first . if its a controller then ill assemble what i have and see if it will work . If its magnets then im really considering making this a reality (after sending you one thud)


ive got more of the rotor blanks and enough magnets coming to fill them all . the stators should be just as easy to stack , small tack weld and then wind them . the old alternator case could be easily stretched with longer bolts so later i go to pick up my custom wound stator and then ill strip 3 of the old ones and see how it looks. hee hee hee

hhmm looky here . out of the 4 of them i got this one is wye all the rest were or are delta.

[def215]

does that mean its almost together enoob? looks like its starting to come together. all these pics are inspiring me...lol

[enoob]

def215 im so close i can taste it. i was supposed to have the stator last week but oh well got it now . wife has the boys and the camera gone to see santa (for the third time) at the mall . as this is the busiest shopping day of the year i opted not to go. she's a nutter.

So once the wifey gets home ill post a shot of it. other than that i just have to bore out the hole for the shaft and press the rotor on and she's ready . working on that right now.

then i need a controller . sigh. at least the folks at kelly are fast , traded repeated email with them last night and im glad i did . confirmed my thoughts on sensored although i will add this from her email about the sensorless , my question concerned the "beta unit" red lettering on their web site for the sensorless units and whether or not they were available yet.

quote
"Yes,the KSL controller has been available.But it is designed for fan,pump,compressor,not for EV.
So I guess it is not what you need.First it will run with a very low speed when the power is on immediately.
It couldn't do regen brake.

For the eBike application,we will suggest you can use the controlle with hall sensor.

Thanks,
Fany"

dont care about the regen and the soft start may be a good thing but ill play with that later. my KEB48400 is en route and apparently ill have it before xmas

[enoob]

back in the saddle folks .

the best part is these are (like a day or so ago) a few teasers . the rest now i save so i can drop a bomb or show off my failure.
first up is the stator i like with the thin lams, 1 mil lfp with 12 turns and room for more. the 10si's are more than 2 mil and only room for about 8 turns


and now im getting out the heavy gear for production those paying attention will begin to notice more than a few different units all in various stages .


sparks are cool , funny they never look as good in the photo . with that chop saw i didnt even have to bother taking the guts out .



and now please excuse the wood . its just a method to transfer the hole pattern to the aluminium holding the bearing. i chose to use the shaft from the old starter rather than the one that came with the alternator . this allowed me to get by without coupling shafts but made me rebore the rotor . at this point im doing a final fit and assembly with some pretty'ing up to do and she's a goer.



and this i thougt id throw in the mix . something tells me i may need it soon . anyone know what it is

[Thud]

That ,my friend is OBVIOUS!
Its a cone alignment jig for setting up your Light Saber bearing alignment.
I would prolly build wheels on it.
I am liking the progress.
did your controller get there yet?
I wanna a video of it spinning & winning!

[AussieJester]

Its a cone alignment jig for setting up your Light Saber bearing alignment.

HAHA...

It IS a manual MOTORCYCLE tire changer minus the grip handle...pop the top part off, drill some mount holes to suit car rims in the circular disk and it could also do a car tire ...looks like a HF model too

Next "mystery item" please enoob


KiM

[enoob]

thud , them jedi's better look out darthenoobius cometh.

Funny thing your both right, nice eye kim it is a harbor freight motorcycle tire changer that will soon be building and true'ing bicycle tires assuming i get the power i wish and can start on my own chopper frame that will get a big fat motorcycle tire

the controller sits unopened at the local ups store as i missed him monday. as my hall sensors have NOT gotten here its not my main priority though its killing me not to touch it, hug it and drool. i thought i had a lead on some halls local and nadda. ordered some from digikey and nothing yet been checking the mail every day like im sposed to be getting a winning lotto ticket or something.

after seeing what Burtie did with that outrunner im gaining confidence that i may get lucky enough to pull off a hall sensor install so ill crack that egg in the morning and see what shakes. if i cant get hall sensors by the weekend ill get that cc from the lhs and push some juice. gotta find out if this works before i get sucked into grabbing more alternators. the collection is stacking up .

[AussieJester]

after seeing what Burtie did with that outrunner im gaining confidence that i may get lucky enough to pull off a hall sensor install .

I like Burtie hes such a quiet achiever, hear very little from the fella then BAM some very very cool posts in his worklog including vids...I very much like they way he has attached the hall sensors...i still have no clue where to place them or how to wire themz up, Bubba<--another 'quiet achiever' has toldz me he will be taking some detailed pics when he does his though so :: fingers crossed :: i'll have abetter idea of what the go is...

KiM

p.s did the MSN invite come through your end enoob?

[dontsendbubbamail]

:)and now please excuse the wood .

Real men are not ashamed to use wood.

Bubba

[Thud]

wood is good.

this is nothing of my doing.......just a snarfed photo.

[enoob]

Real men are not ashamed to use wood.

Bubba

you know i try and tell the wife that but she just wont listen....


love that bike thud. i wanna make one . but how am i gonna tell folks im gonna go ride my woody .






ok i think ive had enough fun with the dirty's

[enoob]

ok i lied. its the weekend and it has not spun yet. BUT i have made progress and feeling like i should share a little since i talked out my butt about it spinning this week.

went to main electronics today and low and behold they are 2 doors down from ebike.ca AND they had these in stock


so now im rather excited as i have everything i need to make it work . i just have to add the rest of the leads, shrink the shrink wrap and install them in the stator. i intend on copying burtie and position them in the stator using the same epoxy that i used for the magnets (unless some one sees a problem) leaving the face of the hall exposed . ill be patient and let that set for 24hrs and then its GO TIME.

side note . got me some 555 timers as well . heres a stumper for ya kim , guess what those are gonna do ? hint i got orange led's to go with.

[AussieJester]

side note . got me some 555 timers as well . heres a stumper for ya kim , guess what those are gonna do ? hint i got orange led's to go with.

Your going to make a simple pulse width modulation speed controller for your motor with spiffy flashing
organge LEDS LoL..

Best of luck getting th motor up and running mate

KiM

[enoob]

Your going to make a simple pulse width modulation speed controller for your motor with spiffy flashing
organge LEDS LoL..


KiM

lol i wish i knew how to do that .

im gonna rig up a little turn signal/brake light setup, drill some holes in the rear fender and try and make it look like it belongs there.

[AussieJester]

Your going to make a simple pulse width modulation speed controller for your motor with spiffy flashing
organge LEDS LoL..


KiM

lol i wish i knew how to do that .

im gonna rig up a little turn signal/brake light setup, drill some holes in the rear fender and try and make it look like it belongs there.

Well yes.... that was my second guess

KiM

[etard]

Nice work here Enoob, I am jealous of all the time away from the wife you are devoting to tinkering, I have a full house rehab going on right now. but she promised me a garage after all this is done, so I will be in the mix soon enough. Anyway, my question is how do you guys know where 120 degrees is? I mean, do all of these motors inherently have three vectors off the axis, or is there always segments divisible by three? I hope this is clear, cause it's kinda muggy on this end. I want to put in hall sensors eventually and am not sure how the guys are figuring out the placement.

Carry on good sir.

[enoob]

dont be to jealous . i pay for the time i take but then her knowing that i put other things down to spend time with her (shiver runs down my spine) tells her she still means something in this relationship. riiiiiight.

along the way i devised a few ways to work through that problem but the easiest turned out to be math of all things. yuk.

these stators have 42 gaps between 42 poles, 120 is 1/3rd of 360 so divide the gaps by 3 gives me 14 even, so install one the next gap is 1 count to 14 and install the next.
ill have photos hopefully in the morning.

[enoob]

well looky what fell onto my desk last night.
this unit is not mine but i have the go ahead to test with my motor and see what happens . should it work ive been comissioned to build a bike around it so here i am asking what are some simple questions but with some success will create another convert to the e-side.
would LED's work to cap the voltage of that 7.4v lipo cell to a forward voltage of 5 to power the servo tester?


today and tomorrow should prove interesting . i have over 100 photos and 20 mins of video to edit and share and i have yet to apply voltage to the motor to test so more footage cometh . You guys will be there with me win or lose so get ready soon i will flood this thread with photos. hopefully without having to open the garage door to let out the smoke

[johnrobholmes]

Since you have that logging ESC you can pull all kinds of info from no load tests on the motor.

[enoob]

Since you have that logging ESC you can pull all kinds of info from no load tests on the motor.

the gentleman that stands beside me says he will have the usb device i need to see that data come friday so before i get home and google it do you know how much data the esc stores ? or is it live?

[Thud]

kinda small but it looks like this:


I was tracking:
Pack voltage: max 35.2 min 30.2 avg 0.3
ripple: max 4.32 min 0 avg .12 (thats what happens when a anderson conector comes unpluged
jumpimg curbs )
current: max 104.6 min 0 avg 12.9
amp hrs consume rate: max 4.82 min 0 avg 2.67
watts: max 3132 avg 386
controller temp: min 53 max 134 avg 78
rpm: max 25521 avg 3914 (lots of coasting)
throttle input: confusing #s
power out: more confusion avg 27.1 max100

This was a play session in the front yard mostly trying to perfect a wheelie technique & couple quick blasts up & down the road to the corner store to corner on pavement maybe 20 mins of abuse.