RC Cargo Bike - reduction drive 95% complete pg8

[damonjackson_spl]

this is an interesting charger?

could I use this to my odyssey battery instead of my arlec 4amp one?

http://www.ebay.com.au/itm/New-12V-24V-60amp-Power-Tool-Battery-Charger-Starter-/260794949652?pt=AU_Car_Parts_Accessories&hash=item3cb8972014

[etard]

How come you are charging using an $800 battery instead of through a power supply like the meanwell or any other power supply?

I think the last 5% is usually the charger balancing the batteries, at least that's how my charger works. The 1420i might balance as it charges.

[amberwolf]

saying they were charging to 95% pretty quick (with good C rate) and the last 5% was taking agers, maybe Graeme said back the charge cycle down to 95% and it'll charge quicker.. like a fine tuning to get the pack done even quicker!!

Just remember, you'd only be charging to 95%, so you'd only have <95% of the pack's capacity available.

The last 5% is probably taking a lot longer because it's either balancing at that point, or it's so close to the charger's output voltage that it can only put a tiny trickle of current thru the pack, and thus takes a lot longer than when it could pour it in there.

[damonjackson_spl]

How come you are charging using an $800 battery instead of through a power supply like the meanwell or any other power supply?

I think the last 5% is usually the charger balancing the batteries, at least that's how my charger works. The 1420i might balance as it charges.

the battery is out of my 1965 dodge pickup, i read through the hyperion instrctions and said you can use a 12v SLA as a powe supply, I am ordering a big MW 600W 25amp power supply shortly, I just wanted to balance up my packs in the meantime while i am waiting for the power supply (I didnt spent $800 on a battery to charge my lipo )

[Hillhater]

this is an interesting charger?

could I use this to my odyssey battery instead of my arlec 4amp one?

http://www.ebay.com.au/itm/New-12V-24V-60amp-Power-Tool-Battery-Charger-Starter-/260794949652?pt=AU_Car_Parts_Accessories&hash=item3cb8972014

Hmm, ..expensive way to get a high amp power supply .
You could consider one of these .. 40A @ 12v... $30 ...
http://www.ebay.com.au/itm/DELL-POWERED ... 1c1aaecc6d

[wineboyrider]

Yeah he had the battery already. I use a marine battery for my hyperion all the time

[damonjackson_spl]

my MW 14.6AMP 24v power supply should be here in a few days which will be good for bulk charging!!

on a side project, I have got Adrians CB all setup on my van moof 29er, just getting a battery bag shortly (as the one I bought from china ended up being tiny)

I am going to use my CC HV160 6S 4P pack on it, however it is not stuck in govenor mode, I have taken the CC and my castle link into my office to reprogram it as I thought I had 12S selected (but auto select was selected) so I will try it again tonight ans see what is happening. I thought it was my throttlizer, but I bought a new servo tester (unmodifed) and the motor still wont turn but still beeps 12 for 12S and 6 for 6S when i pluf in different packs?

weird

[damonjackson_spl]

Update

Well I used the castle link and checked the settings. All is well so upgraded the firmware and re installed on my bike and bam it all works!!! Even my old modded servo tester throttle. So just waiting fir a battery bag and I'll run the CB for a while while I fab up the cargo bike.

[deVries]

Update Tue Jun 28, 2011 5:02 pm

Well I used the castle link and checked the settings. All is well so upgraded the firmware and re installed on my bike and bam it all works!!! Even my old modded servo tester throttle. So just waiting fir a battery bag and I'll run the CB for a while while I fab up the cargo bike.

How did the bike turn out? I'm hoping for an update w/pics and/or video

[damonjackson_spl]

Oh boy.

I've only just got back into these projects!!

Will have something shortly once I throw a few hours into it!!

The reason for slow progress is because of July this year ive started my own residential design business and have been absolutely flat out!!

Check back later!!

D

[damonjackson_spl]

With determination and careful use of basic tools I have knocked over most of my holes in my plates.

All pilot holes drilled. Pilot holes for M5 thread ready to go, and 28mm bearing hole drilled with a 2pm seat using a spade bit!!!! Remarkably it has worked out perfectly!!

Some pics....
I think I need to revisit my pulley ratios too

[sico]

Nice work with limited tools mate

It's really taking shape now. Will you hold the bearings in with circlips on the shaft or what?

Cheers,

Simon.

[damonjackson_spl]

Yeah probably circlips or maybe locking collars now that I'm mounting everything inside the plates now.

Got my new M6 tap and got the holes all done. Also my bro dropped off some stainless hydraulic tube that has the perfect ID for my M6 bolts so nice precision and zero slop joint the two plates together!

Bit of a design update, since the spade bit 28mm bearing seat worked so well, adding another stage is pretty easy. So going all chain drive, shadow conspiracy 1/2 link bmx chain.

6t to 25t alloy bmx sprocket - 1st stage
6t to 16t acs cross fire - 2nd stage
6t to 33t crank drive - final stage

So about a 51:1 reduction and hopefully around 100rpm at the cranks.

More info coming.

[damonjackson_spl]

Ok quite a big update.

Found a freewheel adaptor from my old hybri-ped setup from 66cc days, just need to redrill to 12mm and tap grub screws


All holes finished and motor mounted, triple stage fits nicely.


Mounting sprockets inside the plates


89mm hole saw ripped the 10mm alum nicely


Stainless tube spacers work very well!!

[sico]

Nice work Damon, that is going to have a mountain of torque at 100rpm ... will the bikes drive train handle it? Or will you tone down the amps to make it managable?

Simon.

[damonjackson_spl]

Yeah should be a hill climbing machine.

I was going to update this thread or was thinking of starting a new one, I'm now running this reduction drive on my Giant DH team with full xtr drivetrain. All freewheels have been ordered. Decided to use the ACS crossfire 16t for the freewheel on the drive, and 22t for the crank freewheel. I have ECHO trial cranks with Isis bottom bracket which is all good gear!!

I have also ordered a Taiwanese torque limiter in 15mm shaft and has a keyway, so looking at what to do to get it adapted to my 12mm shaft, the O.D is 50mm and only $21 aud with free postage, so I'll let you know if it is junk when it arrives.

I have 2 more plates ready to make a 2nd drive, I'll definitely put a 3rd bearing on the motor plate, I didn't do it on this setup cause I thought I'd be running the cogs on the outside of the plates.

Work to do:
Buy 24-25t bmx sprocket that can be machined out to fit the torque limiter
Cut shaft and install circlips
Machine out freewheel adaptor to 12pm and get locking screw setup
Adapt torque limiter down to 12mm shaft
Setup 1/2 link chain to each reduction
Then rock out with my cock out!!!

[Byte]

Link to the torque limiter?

[damonjackson_spl]

Byte


link to torque limiter 50mm O.D, it used a 0.59" keyway shaft, I think same shaft specs as the sickbikes jackshaft = $22 shipped to Australia
http://www.ebay.com.au/itm/380394100706?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649



link to ACS crossfire in 13T-20T (i just bought the last 22T) for $19.95 plus $10.95 shipping, but the guy will combine shipping, I got 2 freewheels for $10.95 shipping = so $25.00 each shipped to Australia
http://www.ebay.com.au/itm/230650710651?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649



also got a nice new PARK chain breaker pretty cheap = $35 shipped to Australia
http://www.ebay.com.au/itm/380396914765?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

[Byte]

Nice Curious how the torque limiter will perform. Good luck with the build! Looks awesome

[etard]

Wow! Nice find in the torque limiter/ slipper clutch. I might have to pick one of those up. Also very impressive job with the spade bit beating cups, didn't know spade bits work in aluminum that well. Another Giant DH build? That's gotta be like 5 or 6 and I want one too! can't wait to see it come together man, keep pressing on!

[damonjackson_spl]

Was my 29th bday yesterday and got some great news. One of the fabrication sheds at my bro's work is closing down and there was an auction to employees for the gear inside. He was the only bidder on their $10k compact lathe that they have only used for polishing stainless. He won it for $730 and we are going halves it in and the bday twist is it will be setup in my workshop at home!!! The lads found about $2000 worth of accessories for it as well line a 4 jaw chuck etc.

Let the machining begin!!!

[kfong]

That is one nice lathe. Tools as well!

[damonjackson_spl]

Ok quick update.

Ordered 2 Dalton slipper clutches and realized once they arrived they were pretty massive.

Being a tight ass I decided to practice some lathe weight reduction machining!!!

[Byte]

Woah that thing is huge idd! Thought they were far smaller lol

[damonjackson_spl]

lol

I'm probably going to loose 500w in just spinning that big limiter :s