Search found 127 matches

by hallkbrdz
Jan 12 2021 8:56am
Forum: Large EV General Discussion
Topic: Electric kart
Replies: 186
Views: 44076

Re: Electric kart

Agreed - great build as always.

Louis - 250cc shifter - is that a vintage kart engine? 80cc, 125cc, 175cc - but I've never seen a 250cc engine.
by hallkbrdz
Jan 09 2021 7:57am
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Where did you get the printed parts from? I went though Craftcloud, and the actual printer was DTEV LLC in Vero Beach, FL. I can't believe they shipped something so poor in quality. The reason I am making my own holders is to allow the cells to go end to end and eliminate welding. Placing them end ...
by hallkbrdz
Jan 08 2021 5:09pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

The good: The 3D printed parts showed up today The bad: Some are unusable due to layer shifting and sticking to the printbed. Waiting for re-prints. I should just buy a printer - but... I thought sending the job to someone who does it all the time would be better for the first crack at it. I'll have...
by hallkbrdz
Dec 30 2020 5:40pm
Forum: Battery Technology
Topic: Spot Welding Copper Strips to 18650 Battery Cells
Replies: 433
Views: 69652

Re: Spot Welding Copper Strips to 18650 Battery Cells

Now just need to attach some balance leads (no BMS in this pack). Any recommendations on compact connectors I can mount on the packs for the occasional balancing exercise (99% of the time these packs will just be bulk charged). Was thinking of either sub-d or pcb headers. I'd recommend surplus mil-...
by hallkbrdz
Dec 27 2020 7:32pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Latest video is now up... enjoy.

by hallkbrdz
Dec 27 2020 11:35am
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

I'm STILL waiting on the 3D printed parts to arrive, or even a confirmation email that they have shipped. However the strip copper from Georgia Copper showed up ahead of Christmas so I can get started on the connector strips. I was hoping to make an upload a video with the new printed parts... but i...
by hallkbrdz
Dec 17 2020 4:23pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Teaser for next video...
Kart Battery 2 Sneek Peak.png
Kart Battery 2 Sneek Peak.png (730.47 KiB) Viewed 334 times
by hallkbrdz
Dec 16 2020 11:25pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Enjoy... more to come as soon as the 3D printed parts arrive.

by hallkbrdz
Dec 05 2020 5:16am
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

by hallkbrdz
Dec 03 2020 10:20am
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Using the correct units now... For the 4x5 bars the square area is 44.7mm, larger than a 1 AWG wire. For the 2x10 bars the current flow is 50.19mm, larger than a 1 AWG wire. For the battery connection bars the square area for that narrow section is 55.27mm, larger than a 1/0 AWG wire (larger mainly ...
by hallkbrdz
Dec 02 2020 1:36pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Spot welding... been there, tried that. MAYBE that is possible with a high power spot welder, but defiantly not with a KWeld (it will just timeout at 200ms). The thick copper bus bar absorbs the heat energy too quickly. Also using a MOT solder station does not work well. For me that was because of t...
by hallkbrdz
Dec 02 2020 12:38pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

That had too much flux on it, I want it all removed. I had added water-based flux, but the resin flux from the middle of the solder is what you see. Several posts suggested this, so I ordered some ethanol to dissolve the solder flux quickly.
by hallkbrdz
Dec 01 2020 8:26pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

I finally have a useful method (still needs some refinement) to produce bus-bar nickel strip sandwiches for my battery!

Video to follow soon.
vlcsnap-2020-12-01-19h17m11s819_sm.jpg
vlcsnap-2020-12-01-19h17m11s819_sm.jpg (237.25 KiB) Viewed 490 times
by hallkbrdz
Nov 25 2020 5:32pm
Forum: Motor Technology
Topic: Dana TM4 TAU Software
Replies: 0
Views: 105

Dana TM4 TAU Software

Just curious - anyone have experience with the software for the ACX1 controllers?
by hallkbrdz
Nov 25 2020 5:22pm
Forum: Battery Technology
Topic: "Copper/nickel sandwich" buses for series connections
Replies: 38
Views: 2807

Re: "Copper/nickel sandwich" buses for series connections

Here is one company from Battery Digital Days that presented a few products that are both electrically insulating and heat conductive potting solutions:

https://www.epoxies.com/products/thermally-conductive/
by hallkbrdz
Nov 22 2020 10:29am
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Pouch AMP20M1HD-A C-rate and max amps are not right in your table :) Due of that also my 4kwh battery specs are wrong in your excel. As I know AMP20M1HD-A has 15C or 300A. Noted. I don't remember where I originally obtained those values. The site I referenced in the spreadsheet now shows it as: &qu...
by hallkbrdz
Nov 20 2020 8:29pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

If you are using the spreadsheet with lower power motors and cylindrical cells, I would download a new copy. I improved it for these, as before it only used high C test results, which are not as valid for low power motors. This improvement uses the runtime to determine the continuous amperage from t...
by hallkbrdz
Nov 19 2020 5:57pm
Forum: Motor Technology
Topic: feedback pls on Motenergy ME1616
Replies: 5
Views: 382

Re: feedback pls on Motenergy ME1616

To deal with the sevcon, you really need to know what you are doing as the (paid!!) accompanying software is very buggy, documentation not exhaustive, unclear and if you run into problems its virtually impossible to get any assistance both online and irl. How they dare to sell this to end users is ...
by hallkbrdz
Nov 17 2020 3:11pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Thanks for your comment! :D

Hopefully it gets better as I go along. There will be much more video from now on.
by hallkbrdz
Nov 17 2020 8:06am
Forum: Motor Technology
Topic: feedback pls on Motenergy ME1616
Replies: 5
Views: 382

Re: feedback pls on Motenergy ME1616

This may help you decide, or at least show other options available. See links below video for the spreadsheet:

https://youtu.be/xKfQeJxk5RA
by hallkbrdz
Nov 16 2020 2:09pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Episode 2: EKartGo Spreadsheet

This episode shows how to make use of the EKartGo Spreadsheet. Includes selecting a battery runtime, motor choice, and a controller choice to provide resulting battery solutions.

by hallkbrdz
Nov 13 2020 9:13am
Forum: Large EV General Discussion
Topic: Electric kart
Replies: 186
Views: 44076

Re: Electric kart

Nice heatsink/mount design, and now with quattro ventole cooling for the motor. :thumb:
by hallkbrdz
Nov 12 2020 8:08am
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Planned episodes: EP01: Intro - Done! EP02: A Salt and Battery EP03: BusBar Mania EP04: Avoiding Wiring Spagetti EP05: It's all about the BMS EP06: Charge! EP07: Merry Christmas EP08: Batteries Included EP09: Ground Control to Major Tom EP10: Velocity Control and Cleanup EP11: First Spin! EP12: Up i...
by hallkbrdz
Nov 12 2020 6:49am
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Introduction video for my project. More to come!

by hallkbrdz
Nov 05 2020 3:41pm
Forum: Large EV General Discussion
Topic: EKartGo Project
Replies: 52
Views: 3508

Re: EKartGo Project

Requested information and testing for the Peregrine 60 144v motor. Nix the heavy under-powered Motenergy motor series, I'll wait and make 2021 fun with this instead.