Ninja 250 conversion: Need some direction

[Doctorbass]

Just a little update... I took my motorcycle enforcement class this weekend, it took about 11 hours a day both Saturday and Sunday. I passed!

Congrat!

Now.. the ebike need your work!

[tostino]

I know I need to get going with it! Do you have any idea what I should use for some high temp solder for the tubing? I need to get some of that pretty soon if possible, and I don't even know what to look for as far as solders go.

P.S. what do you think of my cap choice?

[tostino]

Yay I got my leaded solder paste in the mail today!

[tostino]

Take a look at my sexy new caps! I soldered on three of the 6 total I want to put on the bottom of the board, because the other three need to be put on after I am done putting the fets/wires in.

[Arlo1]

Did you decide on a motor yet? I think collossus would be good!

[tostino]

If I can get the colossus, thats what I want to use! It seems like a better fit than the ME0913.

Higher rpm limit, more efficient, better cooling, lighter, probably more powerful... whats not to love?

I already talked to Burtie about getting a timing adjuster board, and am on the list for that. Now I just need to get Markobetti to respond to me so I can get in line for a Colossus lol.
Hopefully the Colossus will like my 150v setup, and not just want to murder my controllers lol. I'm hoping that by running the two 36 fets, i'll increase the motor resistance enough by splitting the windings, and the controllers will handle it well.

I'd sure love to see a 130mph top speed :p

[pgt400]

Nice work, which batterys are you going with? The Ninja is a great base. Be sure to brace the frame, the engine is a structural part.

Phil

[tostino]

Well, it's been a little while since I've done anything with the bike project. I got a promotion at work though, and now I actually make a little extra money I can use on this project as opposed to before :p.

So let's get right to it!

I got some more 1"x1/8" color bar, cut it to length and sanded it smooth.


Then I make some yummy dinner! :p. I soldered two lengths of pipe onto each of the 4 copper heatsinks.


They are just long enough for the two rows of 18 fets on my 36 fet controllers

[tostino]

So, I got a present in the mail today... the other two are still on their way.
http://db.tt/zjgkoQRW
http://db.tt/OCI4bgy2

[grindz145]

Watercooling FTW

[tostino]

Wow... just looked at the pics on a regular comp (not my tablet) and they are all frocking huge lol... I'll resize em now.

Edit: Fixed =)

[tostino]

So I am getting the remainder of my water cooling parts in the mail today!
I got one of these, three of these, and lastly one of these.

I'll be testing the heat-carrying ability of the system as soon as I get everything in. I'll just need to make a hot-plate of some sort that I can measure the power going in. Pictures to come tomorrow.

[Gordo]

What will you use for coolant? Pure water or glycol mix?

[tostino]

Most likely pure water... I live in Florida, we get a couple freezing nights a year. If anything, I will mix just a little glycol in with it, because we will never see temps below about 30f for more than an hour or so.

[farmkid4]

Any updates? I very interested to see how this goes.

[deVries]

Sat Feb 12, 2011

I actually have no idea how I would couple the motor to the transmission if I were to go that route. Have there been any other builds that have used the tranny? I've had a hard time finding that info, but then again, I'm browsing with my phone which isn't always the best for finding info lol.

Check this recent thread.

http://www.endless-sphere.com/forums/vi ... 10&t=25160

How large of a battery do you think I'll be able to fit on the bike? I was thinking about 36s 30ah or 40ah.
I saw in another thread on an electric dragster, Luke said to use some copper bussbars and solder thick male bullet connectors for all the packs in parallel, and use the bussbars for series connections too. I loved that idea, because it seemed so elegant, and allowed for any size pack. I was going to use 6s5ah packs and put 6 to 8 (or more if they will fit) in parallel, and 6 in series.

36S is pretty high voltage, Most of the 15-20kW motors are 72V systems and would break if you put them on 130V. I think I would go with 30S max. Or maybe 20S to start with, and then increase the voltage if you want more speed.

To begin with I would go with maybe 4 of these 4Ah 45C 10S packs, 2 parallel, 2 series
http://www.hobbyking.com/hobbyking/stor ... duct=14614

That would give you 74V 8Ah (592Wh), but more importantly the capability of drawing 8*45 = 360A (probably about 21kW) for less than $500 and only weight around 10 lbs. That would give you a really good performing bike, with very minimal battery expense, and it would be really easy to integrate into the chassis. Once you get familiar with the motor and all the electronics and the average power draw and the range you want, you could decide how much battery you want, and either add to the pack with the same cells to get the range you want, or design a large battery using cheaper cells. Those high discharge cells end up being about $0.87 / Wh (if their spec sheet is accurate) which isn't bad even if you are assembling a large pack, from my experience the cheapest lithium cells are around $0.5 / Wh, and I have paid as much as $3.25 / Wh, but I haven't looked at battery pricing very closely recently. Be careful when looking at prices / kWh on the internet, most companies lie about the actual capacity / capability of their cells. My bet is that by the time you are done experimenting and what not with a small high-discharge battery, there will be a better / cheaper battery solution available for your full range pack, and you will have a much better idea of what you want your pack to accomplish.

I am interested what do other people think of my suggestions?

-ryan

I'm no expert, just an interested learner wanting to do a motorcycle build at much lower speeds, but your suggestions seem excellent & very knowledgeable.

I'm not certain how fast motor tech is moving, but I'm curious what you would recommend today vs this post last year in February 2011? Thanks!

Anything new with your build Tostino?

[Biff]

I'm no expert, just an interested learner wanting to do a motorcycle build at much lower speeds, but your suggestions seem excellent & very knowledgeable.

I'm not certain how fast motor tech is moving, but I'm curious what you would recommend today vs this post last year in February 2011? Thanks!

Anything new with your build Tostino?

If I were to build something today, I would go with a Motenergy brushless motor with a sevcon controller. There are some advertized here: http://www.electricmotorsport.com/store ... s_kits.php the kits are a little pricey, compared to buying the components separately, but making sure the sevcon controller is programmed properly to run the motor is not an easy thing to do.

If you don't want to mess around with brushless the good old Mars or Agni Brushed motor with an Altrax controller is an easy solution.

One thing I forgot, is the Enertrac hub motor. If you want something really easy and have plenty of room for batteries, a hub motor is the way to go, and the enertrac gives enough power for city type riding.

-ryan

[Biff]

It looks like Zero motorcycles is interested in selling their motors / controllers / batteries.

http://www.zeromotorcycles.com/powertrains/

[Arlo1]

It looks like Zero motorcycles is interested in selling their motors / controllers / batteries.

http://www.zeromotorcycles.com/powertrains/

$?

[Atom72c]

Motenergy me0913 is a grate axial flux motor and is capable of being over reved but make sure its the b version the original version of the me0913 has bad hardware holding the rotor to the shaft and are known for coming loose and backing out into the stator or worse the rotor running into the stator but that's all been upgraded with muct better hardware, and also the me 0913 was also limited to rotor rpm I have had one fly apart from the inside out, but the a and b version have had that problem rectified with a stronger aluminum alloy. Other than that ive put over 480 amps to the motor with a khb72701 and it held together over 7500 Rpms but I wouldn't push it past its peak for long cause too much heat will cook magnets