Electric Race Bike

[Jay64]

Ken, if you want to check out some awesome electric bikes (bicycles) you need to check out Drew's builds. He is in Orlando too. Stupid fast bikes. I love um.

[sflorlando]

Thanks, Yes I have sent him a few PMs's. Id love to see some of his bikes. Crazy fast stuff.

[drewjet]

Maybe when you are ready to work on that pack we could all get together for a nerd session

[jonescg]

The Soliton controller just showed up today. Damn, this thing is HUGE. Glad I went for the JR and not the full sized.

solton_jr.jpg

http://evnetics.com/products.php?prod=jr

Good thing you chose a Gixxer for a donor bike - they really are the wheelbarrows of the sports bike world And your batteries will fit down nice and low. You should be able to sit this thing under the tank cover pretty comfortably.

[Jay64]

Maybe when you are ready to work on that pack we could all get together for a nerd session

Sounds like a plan to me.




Chris,
Yeah, working the basic dimensions out it looks like there is going to be plenty of room. Now I just need to work out the details for the motor mount/battery tray hardware. I've got it in my head, but there seems to be an electrical short somewhere between my brain and my drawing hand.

[sflorlando]

Im totally down for that!

Right now I am stuck on smelly petrol, my bike is currently dead with a smoked hs3540 and scooter is still in the works.

The race bike will be so slick when done. Cant wait to see it.

Ken

[drewjet]

Im totally down for that!


Ken

Awesome. We need to get on this if it's going to get done on time. I am only working part time right now, and pretty flexible, so just pick a day and time.

The race bike will be so slick when done. Cant wait to see it.

Ken

See it??? I want to drive it!!!!

[sflorlando]

Yes I concur. Im a network administrator for a local accounting/tax group in orlando. Once the busy tax season is done, I will have more time on my hands, finally ending these six day work weeks!

[Jay64]

I'm getting a little bit more of a hang of this software. Now I figured I would try and figure out how I was going to do the series/parallel connections of the packs.

[Jay64]

I have the packs paralleled on bus bars into strings of 8 for 40ah. It is kind of hard to tell in these pics, but each bus bar is sticking out 1/2" on opposite sides from it's sister bus bar on the same string to give something to connect the strings to. Each string has a 1/2" gap between the next string to leave room for each string to be encased in 1/4" polycarbonate boxes, and connected in series to the next string.

[Nuts&Volts]

Your series connections look off. It appears you are actually paralleling and shorting the 8p rows together with the design you have now.

You could just make one modules negative busbar be the postitive of the next module and then you wouldnt need any more series connections except to go from the top box to the bottom box.

[Jay64]

I could possibly have it wrong. But I think it might also be a visual thing based on the angle. The strings are only connected to one bus bar per end. The bus bar that is connecting to the adjacent string sticks out farther than the bus bar that connects on the other end of the string.

zippy_small_busbar_series_bottom1.jpg

(199.34 KiB) Downloaded 3 times

The bus bars them selves have either all negative wires connecting to them, or all positive wires connecting to them. Again, excuse my lack of ability in this program, the red wire doubles back and connects to the bus bar above where they come out of the pack.

zippy_small_parallel_busbar_connection.jpg (214.41 KiB) Viewed 198 times

Then I have the bus bar terminal ends connected pos to neg to pos to neg etc between the strings.

zippy_small_busbar_series_bottom.jpg (168.73 KiB) Viewed 198 times

I hope that this clears it up. Or, I possibly just simply have it hooked up wrong. I do appreciate you taking the time to look it over though.

[Nuts&Volts]

The first picture shows where I think you need to have your series busbars and the bottom one shows where I think you have a short/paralleling where you shouldnt

Basically all you need is a jumper from the + of one 8p module to the - of the next 8p module. Then a wire from the + end to the - end on the lower box.

[Jay64]

Another thing that I didn't mention is that each string is flipped opposite to the string next to it. I colored the ends of the bus bars that are making the connections based on the polarity of the wires connecting to it from the packs. So in that first picture that you mocked up, those two bus bars that you are connecting are both pos bars. Maybe I'm doing it all ass backwards. My first thought was to have one bus bar between 2 strings with pos connectors on one side and neg connectors on the other. Then I was thinking that I would like to have each string in a separate poly carbonate box to keep them protected from each other. I was thinking that might make things easier to move around if I needed to re-organize everything to make things fit better.
But like I said, maybe I'm doing it all ass backwards and making more work for myself than I need to.

[Nuts&Volts]

I always try to make my battery wiring/bussing as short as possibly. This eliminates cost, resistive losses, weight and sometimes complexity. You can still have separate boxes, but turn the packs around and then bolt in a copper jumper across the neg and pos busbars like I put. This jumper can just go through an opening on the side, top or end you make in each box.

This is simple a suggestion from my point of view

[Jay64]

I really appreciate the input. I just want you to know, I wasn't trying to argue my point, just give the reasoning behind my layout, and making sure that I fully explained how my layout was setup so that if I did make a mistake, I could learn from it. So, just to make sure I understand correctly, I can have one bus bar between two strings of packs. On one side of the bus bar all the pos from the string 1 connected, and on the other side of the bar all the neg from string 2 connected. That would both parallel all the packs in each string together, and at the same time series the 2 strings together?

[Nuts&Volts]

Yep, just like this pic below. This could become two busbars as well that are in different boxes and connected with a jumper busbar as I have been calling it.

And I just didnt want to sound rude with my suggestions

[Jay64]

I didn't see it as being rude at all. I welcome ANY input. I do have a lot of catching up to do with the rest of the field. I know this version isn't going to be a Lightning beater, but I want it to at least be able to run with them. Also, this is quite a lot of power to be holding between my legs, so I'm more than happy to get it right. Now is the time for me to work out all these quirks, while I have parts on order and waiting.

[Jay64]

Spent most of today working with sketchup. After I did that battery setup, I went to work on mocking up the Soliton JR controller. Had a computer problem/program crash that gave me quite a scare, but some friends helped sort through finding the unsaved project.

[sflorlando]

thats cool! Man I thought my addiction was bad. Looks awesome...cant wait to see this buildt

[Jay64]

Looks like the 3 major components will fit very nicely in the frame.

[Jay64]

Ken, I can't wait either!

I'm more of a racer than an engineer/builder, so I'm just trying to build something that will take me around a track as quick as possible. My problem is that they are never fast enough for me. As soon as I get one built, I take it for a test ride, and then tear it back down trying to figure out how to make it faster. So I don't have any to ride.

[Jay64]

NV, how is this?

[Nuts&Volts]

very purdy. Saves you a bit of copper it would seem and having to wrench around HV. Trust me working with nuts and bolts when you have 100V+ potential under your gloves doesn't instill confidence! This design you just have to slip the bullet connectors in place

Also think about how you will assembly it. Will you have enough room to plug each bullet connector in to the appropriate busbar... Maybe mess around with some cardboard/wood and the batteries to see how easy/hard it is to twist and plug them in where you need them. Since you have the space it may work well to have each 8p be a separate box with separate busbar and a jumper across them.

It could also be useful to put a nice big connector/terminal block to disconnect the top back from the bottom which would allow you to have two lower voltage packs when working on it.

It's looking good!

[Jay64]

Ok, I wasn't able to get a '06 frame for sketchup so I took the sketchup images for the batteries, motors and controller and super imposed them in a pic of my bike in PS. This is along the lines of how I want the finished bike to look.