Search found 46 matches

by NexusG
Nov 24 2020 11:31am
Forum: Battery Technology
Topic: "Copper/nickel sandwich" buses for series connections
Replies: 38
Views: 2828

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

0.15mm copper sheet may be the sweet spot if it's easy to weld with the kWeld
by NexusG
Nov 23 2020 3:30pm
Forum: Battery Technology
Topic: "Copper/nickel sandwich" buses for series connections
Replies: 38
Views: 2828

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

I'm currently doing some soldering tests with the kWeld and 0.2mm copper sheet I picked 0.2mm copper sheet for my battery project but on second thought, it's probably overkill. The battery will be a 16S8P 21700 cells, with a max pulse discharge current of 250A-300A. From what I have read, 20A per mm...
by NexusG
Nov 09 2020 1:50pm
Forum: Battery Technology
Topic: kWeld - "Next level" DIY battery spot welder
Replies: 1220
Views: 181874

Re: kWeld - "Next level" DIY battery spot welder

Hi everyone,
Does a cheap crimp tool like this one is enough to assemble the kWeld ?
https://www.amazon.com/IWISS-Battery-Ca ... 739&sr=8-3
by NexusG
Sep 03 2020 3:49pm
Forum: Battery Technology
Topic: "Copper/nickel sandwich" buses for series connections
Replies: 38
Views: 2828

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

hallkbrdz wrote:
Sep 03 2020 3:20pm
Copper to copper? Probably not, too conductive.

8mm x 0.2mm nickel strip (four wide) to 0.8128mm and 2mm plate copper is what I am doing. Then nickel to nickel (cell).
0.2mm copper strip with a 0.1mm or 0.15mm nickel strip
by NexusG
Sep 03 2020 1:03pm
Forum: Battery Technology
Topic: "Copper/nickel sandwich" buses for series connections
Replies: 38
Views: 2828

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

It's encouraging !
I'm wondering if it's possible to weld 0.2mm copper (or 2*0.1mm) with this method and the kWeld
If someone is willing to do the test, I'm interested
by NexusG
Aug 07 2020 10:27am
Forum: E-Bike Non-hub Motor Drives
Topic: Hardware temperature control tsdz2
Replies: 147
Views: 18702

Re: Hardware temperature control tsdz2

...... Won't engine oil leach the plasticisers out of the blue gear, making it brittle and brake? Who knows. nexusG does this experiment and wil find if that is the case, after a while. I hope he will report his very interesting experiment than more detailed. I have a brass gear so it's not an issu...
by NexusG
Jun 04 2020 3:51am
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 8152
Views: 891176

Re: New "TSDZ2 Torque Sensor Central Motor"

Thank you for your feedback AZUR. I have updated my message The motor that we so much dream of is a torque motor with great power (1000W-1500W), that can be mounted on every bike and with low cost readily available replacement parts. This motor doesn't exist at this time. The Bafang Ultra seems to b...
by NexusG
Jun 03 2020 1:46pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 8152
Views: 891176

Re: New "TSDZ2 Torque Sensor Central Motor"

I still have one of my TSDZ2 filled with 5W20 engine oil. In order to do so, I simply drilled a small hole at the bottom of the case (and motor side) and injected the oil with a syringe. Then I filled the hole with a small screw and that's all. I took an oil with a low viscosity to reduce the drag. ...
by NexusG
May 13 2020 8:34am
Forum: Motor Technology
Topic: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)
Replies: 6444
Views: 471606

Re: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)

I changed the firmware for this new values: - motor max current of 30 amps - battery max current of 20 amps (note that on original firmware this max value is 16 amps) BUT please note this: the limit of max battery current on original firmware is 16 amps!! - I will put this information on the wiki b...
by NexusG
May 03 2020 5:16am
Forum: Motor Technology
Topic: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (r0mko fork, torque only)
Replies: 20
Views: 1210

Re: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (r0mko fork, torque only)

I think this firmware will destroy your drivetrain - chain and cassette as well as the motor clutch and a motor blue gear. Why do you think it will destroy the drivetrain ? Your current ramp is too agressive ? I use torque only 0.20 beta 1 without issue on the drivetrain but I have the brass gear T...
by NexusG
May 01 2020 8:19am
Forum: Motor Technology
Topic: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (r0mko fork, torque only)
Replies: 20
Views: 1210

Re: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (r0mko fork, torque only)

This is also useful for technical mountain biking trails, sometimes you need high torque at low speed I love the torque only and eMTB features on the 0.20 beta 1 firmware from buba silvocross is tinkering with the code in order to implement a customizable eMTB feature Now you only need to increment ...
by NexusG
Apr 25 2020 6:43am
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 8152
Views: 891176

Re: New "TSDZ2 Torque Sensor Central Motor"

Hi All, Just a couple of questions regarding average and max current. I have purchased a 48V TSDZ2 and I am in the process of designing a 14s3p battery as I’m limited on space. It states that it has a 15A motor controller. Can someone confirm that 15A is genuinely the max it will pull? I’m hoping I...
by NexusG
Apr 25 2020 5:44am
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 8152
Views: 891176

Re: New "TSDZ2 Torque Sensor Central Motor"

Thanks you casainho for your great work and contribution to the project
I'm now willing to make the big step and buy a 860C to use this version
by NexusG
Apr 23 2020 5:43pm
Forum: Motor Technology
Topic: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)
Replies: 6444
Views: 471606

Re: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)

Whenever I have to charge the battery, I disconnect it from the engine. When reconnecting the battery, a large spark occurs because the battery is fully charged. A hypothesis for the source of the fault may be the high voltage of the battery, 63V causing a spike in the controller and over time the ...
by NexusG
Apr 23 2020 10:58am
Forum: Battery Technology
Topic: 21700 for low P count battery
Replies: 11
Views: 706

Re: 21700 for low P count battery

I think the 50E is ok for 3P and TSDZ2 current limited at 15A

But for a 2P configuration, Samsung 40T would be best if you want TSDZ2 to operate at max power
by NexusG
Apr 23 2020 10:33am
Forum: Motor Technology
Topic: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)
Replies: 6444
Views: 471606

Re: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)

I see, so a 15S battery will be still the best in terms of efficiency and max RPM, even with the field weakening active But there is also a problem with PWM frequency, leading to bad efficiency at very high RPM, right ? If we apply a very high voltage to the controller, we can burn it. Yes, the cap...
by NexusG
Apr 23 2020 7:03am
Forum: Motor Technology
Topic: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)
Replies: 6444
Views: 471606

Re: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)

I see, so a 15S battery will be still the best in terms of efficiency and max RPM, even with the field weakening active

But there is also a problem with PWM frequency, leading to bad efficiency at very high RPM, right ?
by NexusG
Apr 23 2020 5:48am
Forum: Motor Technology
Topic: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)
Replies: 6444
Views: 471606

Re: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)

Great work casainho !

But this 25% loss of efficiency is when field weakening is active, isn't it ? Since we aren't riding at 120rpm all the time, that's not a big problem

At which cadence the field weakening begin to work ? Also, what is the influence of battery voltage on it ?
by NexusG
Apr 19 2020 6:43am
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 8152
Views: 891176

Re: New "TSDZ2 Torque Sensor Central Motor"

Hi everyone, Does everyone know the maximum operating temperature of the TSDZ2 neodymium magnets ? I'm doing some tests involving oil cooling but I don't know how hot can I go without damaging the magnets 80°C seems to be the limit for standard magnets but AH magnets can operate in temperatures up t...
by NexusG
Feb 19 2020 4:08am
Forum: Motor Technology
Topic: TSDZ2 mid drive with 860C, 850C or SW102 displays only -- Flexible OpenSource firmware (Casainho code only)
Replies: 6444
Views: 471606

Re: TSDZ2 mid drive and 850C and SW102 displays only -- Flexible OpenSource firmware (Casainho code only)

In the german forum is reported, that Tongsheng has completely reengineered the motor in 2020: https://www.pedelecforum.de/forum/index.php?threads/tongsheng-tsdz2-36v-neues-design-2020.73872/post-1379882 almost changed compare to the old version, shell, chip, accessaries inside, firmware I'm afraid...
by NexusG
Dec 13 2019 10:04am
Forum: Motor Technology
Topic: Good value for money 10-15kW brushless
Replies: 17
Views: 1861

Re: Good value for money 10-15kW brushless

Current rating depends on winding choice. A higher kV winding can take proportionally higher current. 200A with kV 50 is 320A for kV 80 You're absolutely right, I completely forgot it ! Anyway, I will put a temperator sensor on the motor because it's the sole way to know if the motor is actually ov...
by NexusG
Dec 13 2019 9:48am
Forum: Motor Technology
Topic: Good value for money 10-15kW brushless
Replies: 17
Views: 1861

Re: Good value for money 10-15kW brushless

Energy in equals energy out plus losses as always.. It’s marginally less efficient as there are some added switching losses and copper losses. Reason is this: You need lower applied volts to reach same rpm with a higher kV motor so there are volts to spare. If available battery volts are higher tha...
by NexusG
Dec 13 2019 9:21am
Forum: Motor Technology
Topic: Good value for money 10-15kW brushless
Replies: 17
Views: 1861

Re: Good value for money 10-15kW brushless

both motors will have similar performance? Simplified and disregarding saturation and heating of motor: Torque constant kT=9.55/kV Torque= kT*I So 80kV motor needs proportional to 80/50 (60%) more current for the same torque as a kV 50 motor with a given current. That’s why you might need a larger ...
by NexusG
Dec 13 2019 5:32am
Forum: Motor Technology
Topic: Good value for money 10-15kW brushless
Replies: 17
Views: 1861

Re: Good value for money 10-15kW brushless

If money is no problem here are top-end motors https://hacker-industrial-solutions.com/ for the q150 its arround 2000€ without tx :shock: That's way too much. I know that some electric paramotor manufacters use European brushless motors such as Paracell, Geiger, etc... they are probably good but no...