Hacking / pimping the Zero Motorcycle

[Doctorbass]

I just took apart few parts from my zero to discover it and i wonder if the little box i saw is what we can call an ECU with the OBDII plug?

I know it is the brain and that eberything from the motorcycle is connected to it but that trapezoidal plug is taking my curiosity?

Luke any opinion?

Doc

[edcastrovalley]

Has the good doctor added any lipo to that bike yet?

[Doctorbass]

Has the good doctor added any lipo to that bike yet?

No lipo.. it will be aume 20Ah A123 pouches finally.

2kWh added for a total of 6 kWh.. just like the new 2012 ZF6 zero have

Doc

[edcastrovalley]

6kWh will be nice! Are you adding some kind of BMS to the extra cells? Either way the charger should charge everything up nicely.

[Doctorbass]

6kWh will be nice! Are you adding some kind of BMS to the extra cells? Either way the charger should charge everything up nicely.

Yes i will add a BMS. it will be a 16s bms ( 16s LiFePo4 is = to 14s LiMn pack voltage).

Doc

[edcastrovalley]

Hmmm, you got me thinking. So you're adding an extra 32 pouches of A123 cells? Do you have a place to mount these on the bike yet?

Also, which CA do you have on your bike? The stand alone version? I really need to get one. I sometimes get a low battery alarm on my bike yet I can fully recharge it with only 2kWhr from the outlet.

Ed

[Jay64]

That sure looks like the ECU that is in most ICE bikes.

[Doctorbass]

I have measured few signal on teh throttle line of my zero and found that the throttle ( the magura grip) is not directly connected to the Alltrax controller. It have the MBB ( Main Bike Board) conneted in serie between those, so it can overide the throttle signal if any faillure on the system is detected or apparently, if speed are under 30 to limit the current.

Just like the Cycle Analyst is doing with the ebrake and throttle overide signal.

So this mean i could bypass that MBB and have the throttle directly on the controlelr to have the FULL power at any speed ( at the price of bypassing any protection on the system.. but if it's momentanous, who care! )

[Doctorbass]

I measured the continuity between the wires that connect to the alltrax and the wires of the MBB throttle input . ( in other words, what kind of resistance the BBM is affecting on the throttle line.

I found that whatever the key is OFF or ON, the white wire have 0.4 ohm ALL THE TIME
and the white/blu wire have 18.4 ohm ( probaly the MBB I/O components that are adding that resistance)

Now, when i reconnect everything except the two throttle wires that connect to the Alltrax and that i measure the resistance between both, i get 2.3 ohm when the key is ON ( wich is close to the throttle grip wires resisatnce themself ( 0.4 ohm) and corresponsing to the standby state ( 0% throttle)
When the key is OFF, the resisatnce is 1277ohm between the two wires.

That mean if i add a switch that make a direct connection of the white/blue wire between the controller and the throttle grip i should have acces to all the power all the time and the only limiting features will be the alltrax programming parametrers

I have found where these white/blue wires connect on the MBB

By adding a switch between those two wires ( the 2 wht/blu , one from the throttle and one from the controller) i will be able to overide the limiting effect of the controller .. I'll have to be carefull for the usage to not have any problem if a malfunction would occur while the switch is activated.

Doc

[Doctorbass]

Yeah.. Pimping my zero.. that's what i'm doing guys

It's what's on the list

-Adding a 15 pin Anderson connection to have an easy acces to fast balance the pack at up to 30A: check
-Adding celllog8 to monitor voltages for each individual 14 cells string: check
-Adding a 75A Anderson connector to charge the battery FAST: check
-Adding 6 additional fused 12V connections from teh DC-DC output for future purpose: check
-Adding the Cycle analyst V3.0: check
-Adding an easy acces RS232-USB cable to program the Alltrax easy without dissassembling the bottom assembly: check
-Adding the throttle line bypass: IN PROCESS
-Adding a cruise control: pending



I have great technical informations relative to the zero motorcycle to share now:

Today with the Cycle Analyst connected and being able to monitor the real time power. I can confirm that the throttle curve of the zero motorcycle power management IS determining the max amount of current that can be delivered to the motor according to the speed of the motor.

That's probably why they added the shunt on the the motor wire. The Alltrax controller itself IS NOT a CURRENT BASED THROTTLE since it it not made for reading on the motor speed. But The MBB of the zero is made to convert it to a current based throttle by overiding the signal on the throttle line according to the speed the motor is and the current reading on the motor.

Also At full speed on flat no wind ( 108km/h) my zero is drawing 12kW and the max current i measured with the not perfectly calibrated shunt is 362A and the battery voltage sag is 6V ( battery was at 56V no load and drop to 50V, wich eman the total internal resistance of the battery including contactor and wiring IS close to 6V/362A = 16 miliohms.

More interresting real life measurement to come

Doc

[deVries]

Also At full speed on flat no wind ( 108km/h) my zero is drawing 12kW and the max current i measured with the not perfectly calibrated shunt is 362A and the battery voltage sag is 6V ( battery was at 56V no load and drop to 50V, wich eman the total internal resistance of the battery including contactor and wiring IS close to 6V/362A = 16 miliohms.

More interresting real life measurement to come

Doc

Good to see you've got your insurance finally!

How does the 16mo rate vs other battery builds???

Look forward to your upcoming tests...

[edcastrovalley]

All great news Doc. In fact I was about ready to look for a shunt for the CA I'm ordering. This will save some time.

I'm also looking forward to see how the "bypass" surgery you perform will turn out.

Thanks,

Ed

[Doctorbass]

You can have more details about the Cycle analyst installation in this thread:

LINK:
http://www.endless-sphere.com/forums/viewtopic.php?f=10&t=40849&p=597603#p597603

Doc

[nechaus]

Sounds like what my kelly does..

it had 3 modes,
speed
Balanced
Torque ( amp control)

[gasfreeearth]

Curious to see how it comes Doc! I'm interested in your additional pack and BMS especially!!

I'm going to start round 2 of mods to the ZF9 here shortly, with a goal of charging at between 6 and 7kw. Currently at 4kw with the j1772 connector. Some more pics and details here: www.facebook.com/lifeoffthegrid

[AussieJester]

Congrats on the purchase, the modding etc. etc, all extremely interesting but one question good doctor, is it faster than you frock monster E-bike! Lol...also good to see you finally have a non frock powered lecky bike..teehee...in all seriousness, keep up the fantastic work you do mate, it's inspirational.

KiM

[Doctorbass]

Congrats on the purchase, the modding etc. etc, all extremely interesting but one question good doctor, is it faster than you frock monster E-bike! Lol...also good to see you finally have a non frock powered lecky bike..teehee...in all seriousness, keep up the fantastic work you do mate, it's inspirational.

KiM

Hi Kim, Sincerely, my zero is slower than my giant. The max speed i got is 110kmh with the zero on flat and 113kmh with my giant

But i know that the zero is electronicly limited in speed and torque... I will need to install that great bypass switch to overide the "brian" between the controller and the throttle

ONce it is done, all the great full power will be availlable to the motor

Doc

[knoxie]

Hey Doc nice work!! dont think I have seen any pictures of you new bike have you posted any? I see you have made the newbie motorcyle owner mistake of hanging your motorcycle key off all your house keys get a leather or a rubber key fob for it Doc and keep it separate, you will find that big bunch of keys will scratch the heck out of the bars and the steering crown.

[Doctorbass]

I see you have made the newbie motorcyle owner mistake of hanging your motorcycle key off all your house keys get a leather or a rubber key fob for it Doc and keep it separate, you will find that big bunch of keys will scratch the heck out of the bars and the steering crown.

yeah .. I know... thanks for the reminder

Doc

[knoxie]

he he I only remind you coz I care ha ha and I have the picture of those bars as my windows background image Love the Zero motorbikes contemplating selling a kidney to get one seriously tempted to buy one, what the heck you only live once and I couldnt think of a better way to go