Norco A-line 144v 200amp Lipo 150km/h build

[Andje]

sooo I'm still doing battery testing. I got all the B cells charged, They all held 4.1+V over a couple days.
I hooked my Hyperion up to my computer via usb, and am now running discharge cycles on all the B cells. It is amazing to say the least; incredibly detailed graph down to the third decimal, and incredibly accurate.
I charged to 4.2 and then discharged to 3.5/3.8 load/resting, got a first reading of mah, and then discharged down to 3.2/3.5 and got the rest of the mah reading. So far, I am getting between 2650 and 3000mah. IR is a bit high averaging at 100mohms.
I am thoroughly enjoying the graphs the hyperion puts out. I can't wait to start testing the "A"cells.
If i get 325 usable cells I can make a 35s9p pack for 12-13 ah at 147v fully charged. That would be perfect for the Kelly.

[sn0wchyld]

subbed mate. I love how many people are getting alines now!! its a shame were not all in the same contry, it'd be wild to have a norko Eline group ride!! Though I fear the pace would leave you a bit bored andje!

a twin hx35 motor... my god man. that's gonna fly.'

edit
that norko was a fing steal mate. good work.

[Andje]

Well, B cells are done, and they all tested at 2500-2800 mah, so within 85-90%, which I can live with. If each cell is 1.35-1.4 mah then a 9-10 p battery will give me 12-14 ah in total. With 144 volts or so I will have a nearly 2kw pack.
A's are testing now.

[Andje]

My buddy just showed me these; seems like an on/off switch I haven't seen listed on e-s before, might be interesting for those of us pushing 100v+. I had resigned myself to a contactor but would still prefer a switch to save weight and space.
http://www.robotmarketplace.com/products/0-SWHELLA2.html

[binlagin]

I'm SO buying one of those switches! Thanks!!!

[zombiess]

Welcome to ES which use to stand for endless-sphere but now stands for Extreme Speed.

Your dual motor setup is going to be certifiably nuts. If you think wire cutters gave you blisters I can only imagine what the rewind is going to do... ouch. Wish I had the skills and patience to do this kind of a project. I could go as far as drawing it, but that's it, rest would have to be done by someone with way more fab skills than me. I'll stick to playing with electronics where I might be able to make a contribution to the community some day.

[Andje]

Thanks zombiess.
Yeah, I'm lucky I found a teacher willing to help me with the project in terms of machining; it does speak to my talents however that I was looking into buying lathes or building milling/cnc machine when I found no company willing to help on the mechanical side. I have mostly only knowledge accumulated from this forum, my own contributions to the pool are mostly building a battery backpack. This motor the kind of project as you say that is easy to figure out and hard to get done; I STILL didn't think I could attempt it until I watched Farfle's thread. I only finally understood the winding pattern once thud and parabellum had explained it. Still, when it's done it will be a unique thing, if not a unique strategy to do a double wide stator.

The motor is moving along; I met with my teacher again this week to talk about the project; he says everything I want to do will be cake. A few decisions to make, but most of the dimensions are limited by what we have already and 150mm dropouts.
I was worried about the axle but he says that will be easy too; so will enlarging the cover hole for a larger thinner bearing and a spacer with holes for all the wires instead of a slot in the axle. Knurling, not a problem. Keyway, not a problem. I was all smiles and we will start it next week; I would hope to be into the winding by mid february.

In other news, I'm not sure the second hand Kelly I was going to buy will make it; I haven't had any further communication from the seller in a few days even though we had all but confirmed the sale. I maintain hope but am beginning to worry.

[Andje]

Well, I had some personal shit go down today, and while trying to distract myself I decided to charge a bunch of my batteries. I happily linked them together, plugged them into the hyperion and there was an explosion. Turns out I seriesd them instead of paralleling them and plugged 207 volts into my hyperion. Sigh... 170$ later and I have a new one on the way. Memo to all; do not try and distract yourself with high voltage stuff if you are in no state to be playing with it.
Such a shitty day...

[ohzee]

Sorry to hear that bud. I can attest to doing shit while not being there mentally so causing issues.

[Andje]

The funny thing is this is actually the second time the same girl caused me to ruin a charger in my distraction. The first time it was reverse polarity to the meanwells. I should really know better.

[liveforphysics]

You're actually a lucky guy. 207vdc taken across the heart is enough to pass your soul onto its next journey if your body takes the shock badly.

[Andje]

Glad to still be here... I was only touching the negative wire at the time, and I was wearing insulated gloves... but teaches me a serious lesson about doing dangerous things to distract from emotional distress; especially things that are only dangerous specifically when you are distracted... I will learn from this.
Also, I feel like I am truly lucky I didn't kill my computer; the hyperion was plugged into it via USB. I was hoping the charger was ok; upon internal inspection the two caps at the inputs were dead due to under rating for the voltage. I replaced them, took off the heatsink and checked the fets. I can't find anything specifically wrong with them, but the machine remains off. The board looks pristine, so I suspect death of the delicate chipset in some manner. Anyone have any idea what would logically happen when you plug too much voltage into a hyperion? What part would fry?

[fractal]

Glad to hear that you're OK. Matters of the heart dont mix well with voltage and current. Be safe!

[Andje]

Thanks man.

I just finished removing the wires from my second stator. When I redo the axle, if I take the wire out of the disk brake side I will have more room to play with in terms of an enlarged bearing hole then on the freewheel side; about 3cm diameter on the side with disk brake could be removed I think without compromising the structure that the disk is attacked too, whereas the other side would be left woefully thin if I were to enlarge the hole. I'd still rather do without an axle slot, even if that means running bundles of uninterrupted magnet wire out of the motor through multiple holes. We shall see if there is enough room.

RIP little buddy... I feel like I killed a pet. I loved this little thing...

deadhyperion.jpg (148.16 KiB) Viewed 462 times

The hole with measurement

middlebearing.jpg (129.07 KiB) Viewed 462 times

And the two stripped stators

two stators.jpg (85.86 KiB) Viewed 462 times

[dnmun]

the connection you made was a total of 200V of batteries on the output? and it popped something inside?

there may be a diode, a zener across the output that blew up because it was overvolted, and the output may have caps that were overvolted, not familiar with the circuitry, but look for them, maybe it can be repaired.

[Andje]

Well, I just retested the fets, and all but one are showing source/gate conduction, so that means they are all dead i think. There is no obvious zener or anything; I don't think it has overvolt protection for 50s... There are two electrolytic caps over the input terminals, those blew, I replaced them.

[Andje]

Well charger shipped, and the kelly controller I wanted is still around! Expensive, but good!

[Andje]

Just sent the funds for my controller and contactor. The name of this thread basically just got confirmed
Dropped of my motor with my prof too; he is going to start on the lathe work for me. As I said, mid February for the wind...

[heathyoung]

Well, I just retested the fets, and all but one are showing source/gate conduction, so that means they are all dead i think. There is no obvious zener or anything; I don't think it has overvolt protection for 50s... There are two electrolytic caps over the input terminals, those blew, I replaced them.

Urk. That also means its gone through the drivers, and probably through the logic as well. Ouch.

[Andje]

yeah that's what i figure. I could poke around with my ttl/cmos probe but I can't really fix anything, it's all smd... I am still quite sad... I feel like it deserves a burial and a headstone... second in what will most likely become a line of small gutsy soldiers...

[Andje]

Prof suggested instead of building a mould and vacuum bagging fibreglass and such, to just fibreglass on balsa for anything not load bearing. I am investigating this.

[Andje]

Well, i ordered a bunch of thermistors and halls, and an arduino mega adk. I can eventually hook it up to an android phone via usb if i want! It is going to take a hell of a long time to learn C...

[MattyCiii]

Arduino's version of C is not so bad. A lot of the ugly stuff is wrapped. I'm assuming from the Android part of the equation that you know Java - if you know Java you'll do fine with Arduino.

[kfong]

Bummer about you Hyperion, cheapest price I've seen is from this vendor $130. I picked up a spare one from him during Xmas.

http://www.ebay.com/itm/HYPERION-EOS-14 ... 1036wt_922

[Andje]

Um... holy shit. My Mouser stuff just arrived. I hadn't been aware I spent 15 bucks to expedite, but i can live with that for 24 hour shipping. Also, Arduino's are WAY smaller then i thought they were!
Now to get it working with EVERYTHING. Probably thermistor and halls first though. If i can get the thing inputting and outputting my hall signals than I can work on digital timing adjustment experiments too.