Brushless dual 6kw ALIEN Power system - electric longboard

Lightweight / Folding / Portable EVs - seats optional

Brushless dual 6kw ALIEN Power system - electric longboard

Postby beetbocks » Wed Jan 23, 2013 8:25 am

Well Hi to everybody out there!! this is my very first post on a Forum ,but having being a forum user for many years i thought i would actually contribute!!
I have started a E-skate project. Having owned an elektroskate off the shelf 500w model which I'm more than pleased with but i do think the single wheel drive is a bit limiting up hill and I live in Yorkshire!!!I thought I could do better!!
so the specs:-
2x 3KW outrunner motors
Alien controller- from my good friend Bruno!! http://endless-sphere.com/forums/memberlist.php?mode=viewprofile&u=27393
Nice long board (undecided yet)
Holey Trucks
Abec !! flywheels 83mm super soft 75 durometer!! (with my custom wheel hubs I can use any diameter of Abec 11 wheel-102mm!! yeah baby)
Wii nunchuck remote (hopefully Bruno??)

I am lucky enough to be a CNC machinist and can do my own parts and use Solidworks fairly proficiently!! I am also helping Bruno out with his Ebike RC motor design http://endless-sphere.com/forums/viewtopic.php?f=28&t=45874&p=691073#p691073.
My intention is to be able to use off the shelf parts and just add the RC system to it.. they can make the trucks and wheel far cheaper and better than me!!
Ive done a few renderings of the finished product and hope it comes out half as good!!
Any comments would be most gratefully received!!
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more-photos
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just waiting for the motor and controller from Bruno!!
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battery box-done!!
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motor brackets done
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board2 - Copy.JPG
how it will look hopefully
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Re: Brushless dual 3KW Eskateboard

Postby Spooky1 » Wed Jan 23, 2013 3:01 pm

Are you saying 1 Alien ESC can be programmed to control 2 motors?

I have looked at Alien ESC's but was slightly put off with the price.
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Re: Brushless dual 3KW Eskateboard

Postby ohzee » Wed Jan 23, 2013 3:04 pm

Looks pretty sweet.. so what's going to protect the case on the bottom metal or plastic ?
Id be concerned with something not pretty tough.
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Re: Brushless dual 3KW Eskateboard

Postby sk8norcal » Wed Jan 23, 2013 5:44 pm

that's very cool!

like how u use the holes in the Holey trucks....

can you put up a pic of the machined cog piece by itself ?

i am wondering, is the cog piece locked down?
seems like it wont be secure enough by just sliding in from the side...
unless it is interference fit...

or like this?
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Re: Brushless dual 3KW Eskateboard

Postby Stielz » Wed Jan 23, 2013 6:26 pm

Very nice, What speeds are hoping to achieve with your chosen gear ratio?
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Re: Brushless dual 3KW Eskateboard

Postby beetbocks » Thu Jan 24, 2013 8:18 am

Spooky1 -
yes Bruno is making a special 2 in 1 controller that will control both motors in one unit- If you contact Bruno on this forum his prices are cheaper than Ebay--:) http://endless-sphere.com/forums/memberlist.php?mode=viewprofile&u=27393

Ohzee-

ill get it all working first then i'll make a carbon fiber cover- ill machine a foam 'buck' or mould then lay into it with cold cure carbon-strong and light!! i will use solidworks to lay a outerskin over the components and use that as a mould pattern..

sk8norcal

Yes i wanted to make a system that could be just bolted on to off the shelf items so if/when the wheels the axles break i can just buy another- Also locating in the holes give a nice positive location so no twisting of the bracket!!
The pulley wheel is all one piece and will be held in place from the front face of the wheel with a hub retainer which i'm making today at dinner time!! I will be making some universal hub drive so i can mess with the final drive ratio ,again the beauty of is it I can use any of the Abec 11 flywheel- just change the pulley teeth to suit the wheel diameter.
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Steilz-
With the 83mmm wheel and a 15/30 ratio i hope to do approx 30mph but be able to go up hills ,hence the dual drive -plus no one else has done dual drive!!! i am really not sure if it will start to pull one way!! we will see
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Re: Brushless dual 3KW Eskateboard

Postby Spooky1 » Thu Jan 24, 2013 11:45 am

What width are the aluminium motor mounts? They do look very nice!
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Re: Brushless dual 3KW Eskateboard

Postby Chalo » Thu Jan 24, 2013 2:42 pm

This is to express my gratitude to Justin of Grin Technologies for his extraordinary measures to save this forum for the benefit of all.
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Re: Brushless dual 3KW Eskateboard

Postby sk8norcal » Thu Jan 24, 2013 4:05 pm

beetbocks wrote:
sk8norcal

Yes i wanted to make a system that could be just bolted on to off the shelf items so if/when the wheels the axles break i can just buy another- Also locating in the holes give a nice positive location so no twisting of the bracket!!
The pulley wheel is all one piece and will be held in place from the front face of the wheel with a hub retainer which i'm making today at dinner time!! I will be making some universal hub drive so i can mess with the final drive ratio ,again the beauty of is it I can use any of the Abec 11 flywheel- just change the pulley teeth to suit the wheel diameter.


cool! i was kind of guessing you were gonna use a "hub retainer"
universal hub drive sounds like a great idea!

With the 83mmm wheel and a 15/30 ratio i hope to do approx 30mph but be able to go up hills ,hence the dual drive -plus no one else has done dual drive!!! i am really not sure if it will start to pull one way!! we will see


i guess you meant "diagonal dual drive", cuz boosted already done 2wd rwd.... (and i just saw a 2wd fwd mtboard)
but I have seen "diagonal dual drive" on older style e-boards...

example...
http://www.e-ride.ca/Electric_Skateboar ... ster.html#
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Re: Brushless dual 3KW Eskateboard

Postby beetbocks » Fri Jan 25, 2013 3:01 am

I must admit the boosted board is my inspiration ... The trouble with that though ( aswell as the price ) is that the wheels
and trucks have to be machined before the motor fits. My system fits on off the shelf parts!!! And my motors are bigger!! :)
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Re: Brushless dual 3KW Eskateboard

Postby Spooky1 » Fri Jan 25, 2013 10:12 am

beetbocks wrote:the actual radius motor bracket is 6mm thick 7075 alloy- they are connected to angle bracket same alloy- easy to make in 2 piece~!! :D



Ok, I have looked online but can't find a plate of 6mm 7075 to work with, but I have found some 6mm 5083 grade, seeing as your a CNC guru could you tell me if this is ok to use for my motor brackets? I don't want to buy shite metal!

I plan on tig welding the end.
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Re: Brushless dual 3KW Eskateboard

Postby Chalo » Fri Jan 25, 2013 2:34 pm

Spooky1 wrote:Ok, I have looked online but can't find a plate of 6mm 7075 to work with, but I have found some 6mm 5083 grade, seeing as your a CNC guru could you tell me if this is ok to use for my motor brackets? I don't want to buy shite metal!


5083 is less than half as strong.

1/4" plate is nominally 6.35mm.
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Re: Brushless dual 3KW Eskateboard

Postby beetbocks » Fri Jan 25, 2013 3:09 pm

Hi
Try http://www.smithmetal.com/ this is my supplier
I actually milled a cut off peice down to 6.5mm- you could use 6082 instead.6mm will be fine. I even think 5mm would have been ok but I like to make sure!!
If you are going to tig weld it though it will severely weaken the alloy, it really needs annealing (heat treating) afterwards.. Also bear in mind the filler rod you will be using in tig will not be 6082/7075.
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Re: Brushless dual 3KW Eskateboard

Postby Chalo » Fri Jan 25, 2013 3:17 pm

7075 is not considered weldable.
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Re: Brushless dual 3KW Eskateboard

Postby Spooky1 » Fri Jan 25, 2013 3:19 pm

beetbocks wrote:Hi
Try http://www.smithmetal.com/ this is my supplier
I actually milled a cut off peice down to 6.5mm- you could use 6082 instead.6mm will be fine. I even think 5mm would have been ok but I like to make sure!!
If you are going to tig weld it though it will severely weaken the alloy, it really needs annealing (heat treating) afterwards.. Also bear in mind the filler rod you will be using in tig will not be 6082/7075.




Bugger I got impatient and bought the 5083, I can always cancel the purchase I guess.

If I do not weld the bracket and drill a bolt though both bracket and axle, do you think the 5083 will be suitable for that?

In terms of strength?
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Re: Brushless dual 3KW Eskateboard

Postby Spooky1 » Fri Jan 25, 2013 3:59 pm

I just looked at the smiths website they recon the 5083 is a popular general purpose alloy with excellent anti corrosion properties, so I'm happy now, out of interest beetblocks where about do you live in uk?
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Re: Brushless dual 3KW Eskateboard

Postby beetbocks » Sat Jan 26, 2013 3:26 am

Hi Spooky
Yes the 5083 should still be ok just go a little thicker maybe. No welding would be better but if u start drilling homes through the axle it will weaken that....hence why I did my design with no welding or drilling.. Just get holey trucks and your away!!!
I live in huddersfield .
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Re: Brushless dual 6kw ALIEN Power system - electric longboa

Postby Stielz » Sat Jan 26, 2013 5:00 pm

Looking good! That's good to see you're going with a sensored setup, I wouldn't go any other way. Which of Bruno's ESCs will you be using?
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Re: Brushless dual 6kw ALIEN Power system - electric longboa

Postby beetbocks » Sun Jan 27, 2013 6:34 am

Hi
Bruno has made a special 2 in 1 controller!! We did away with the sensors in the end the wheel are so small there not needed. We got it all fitted on a donor board yesterday and the results just awesome,,, just waiting for the weather to dry!!
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Re: Brushless dual 6kw ALIEN Power system - electric longboa

Postby beetbocks » Mon Jan 28, 2013 9:47 am

Right as promised a short video for the motors and drive system running.. The results are AMAZING!!! the power is truly phenomenal!! I've had a quick go outside my house and the acceleration as just brilliant and the power delivery is very smooth . I now have to wait for the weather to dry up.
I cannot stress how good a job Bruno has done on the Dual ALIEN power system controller and helping me wire the whole thing up.Cheers Mate!!
I now have to get a nice looking deck-any ideas- I have been looking at a Earthwing Super glider Carbon edition or possibly a Bustin Sportser (from America) its got to be something fitting to suit the nice looking drive system

http://www.youtube.com/watch?v=lLd8BY08w-w&feature=youtu.be
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Re: Brushless dual 6kw ALIEN Power system - electric longboa

Postby sk8norcal » Mon Jan 28, 2013 2:27 pm

embed 4 u,

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Re: Brushless dual 6kw ALIEN Power system - electric longboa

Postby Spooky1 » Tue Jan 29, 2013 2:25 pm

Can't wait to see this running!
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Re: Brushless dual 6kw ALIEN Power system - electric longboa

Postby beetbocks » Thu Jan 31, 2013 3:40 am

Hi
Just a quick update on the project- I had a quick go outside my house and the acceleration is just phenomenal!! In fact it was that hard that it threw the batteries straight out of the back of the battery box (brittle perspex) It was never intended to be the real box but i though it would stand up to the task a bit better!! any way the board is off the road until I make a new ABS vacuum formed one.
I am on with designing and machining the buck to form it over and the ABS sheet is ordered. I have also got a few other goodies to fit and Bruno and I are working on a novel control system but that's to be tested to see the suitability!!
I also have to bite the bullet and by a nice deck to put it all on!! my one of choice (Earthwing superglider Carbon in red) appears to be out of stock everywhere though!!! :(
Ill keep you posted..
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