Electric "tough bike"

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Ruudi   10 mW

10 mW
Posts: 26
Joined: Apr 10 2012 3:26am
Location: Estonia

Re: Electric "tough bike"

Post by Ruudi » Aug 08 2015 4:11am

Didn't find the display at that link but here it was http://www.aliexpress.com/store/product ... 72145.html
seems like not available anymore.
Last edited by Ruudi on Aug 08 2015 4:19am, edited 1 time in total.

Ruudi   10 mW

10 mW
Posts: 26
Joined: Apr 10 2012 3:26am
Location: Estonia

Re: Electric "tough bike"

Post by Ruudi » Aug 08 2015 4:18am

vax wrote:Controller is that one:
http://www.aliexpress.com/item/24-mosfe ... 35975.html

I actually got it for free, since it took very long to arrive, more than 2 months. I claimed the money back and received the controller a week later :D
Wasn't it a bit risky to buy such no name sinewave controller? How did you know that it really is sinewave? Was it that, you know now, that this one really is :) Does it's throttle feel the same as kelly controllers?

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Aug 12 2015 1:06am

Yes of course it was risky. The controller is however very good. Compared to Kelly its very quiet. When riding I can hear only very slight high piched whine. I think its from internal turbulences between stator teeth and magnets, not controller made. Also, the controller is super smooth in action. 3 speed switch is nice. It limits speed to certain levels, but power remains the same so I can accelerate as usual.
The only negative thing about is very weak regen - almost nothing.
Prototype fabrication https://www.facebook.com/3dflux

Shanroy1   1 µW

1 µW
Posts: 1
Joined: Sep 04 2015 9:44pm

Re: Electric "tough bike"

Post by Shanroy1 » Sep 04 2015 9:49pm

Hi I was just wondering if you made the steering column or if it was purchased?

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DasDouble   100 kW

100 kW
Posts: 1095
Joined: Jul 12 2015 1:35pm
Location: GERMANIA :D

Re: Electric "tough bike"

Post by DasDouble » Sep 06 2015 4:39am

subscribed.

Maybe you are interested in the Vector frame from Artur Ragulskyi :)
"..the crazy kid exploring hipower ebike world ^^"
-Built own ebike: ✔
-Built own 3.2kWh LiIon battery (300Amps): ✔
-Overtake Porsche with own Ebike: ✔
-Take off with ebike: ✖

~14kW, 3.2kWh LiIon, QS 205 8ml ff, hubsink

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Feb 27 2016 8:00am

Attention!
Please vote for my bike (project #27) : http://motorshow.ee
There's Tallinn Motor Show today and tomorow, and my bike is one of the hobby projects that competes for 1000€ prize.
I will invest this money to our next e-cruiser project, that will be awesome.

Thank you :D
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Feb 27 2016 8:04am

Shanroy1 wrote:Hi I was just wondering if you made the steering column or if it was purchased?
Steering column is 100% diy, with lathe
Image
Prototype fabrication https://www.facebook.com/3dflux

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minde28383   1 kW

1 kW
Posts: 382
Joined: Apr 02 2010 7:11am

Re: Electric "tough bike"

Post by minde28383 » Apr 13 2016 3:43pm

Hello Vax,
I'm very interested how you made rear frame connection with swing arm (axle). Could you elaborate about it little bit more. I'll put pic of what part specifically I'm interested. Could you give measurements of bearing socket and axle tube wall thinness
What other options to consider? Is it necessarily to use bearings or maybe bushings enough?
Attachments
axle.jpg
axle.jpg (181.22 KiB) Viewed 2030 times
CN 5.5kw scooter resurrection in progress
E Mindless Maverick Talisman longboard, 2.2KW motor, 150Amps controller (gone)
Scooter:Mach 1600w, (sold)
Bicycle: Giant NRS, 2806, ping 48V 15Ah, stock Infineon, (sold)
Bicycle: Trek 4300, 9C, ping 48V 15Ah, Infineon 25A, ~18Wh/km, max speed 45 km, (sold) [/size]

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Apr 14 2016 4:54am

Ok here we go
If you use bearings, it is necesary to eliminate axle tensioning force from bearing balls. So, inside axle pivot, there's steel tube between bearing faces. Also, there's washer between frame and bearing outer face. Swingarm axle tightens everything together.
The bearings are standard 6302 with sealed sides. Basically the sockets are press fit, 0.02mm smaller than bearing outer diameter. Yes you can use bushings, but bearings give smoother movement and longer lifetime. I haven' experienced any bearing failure yet on that bike.
Axle tube is 40x2mm. Bearing sockets go through side plates and reach ca.10mm inside the tube. Finally, they are welded from both side, so it becomes quite strong.
You can download drawings, cut files, 3D CAD model of this bike from my grabcad page:
https://grabcad.com/library/electric-mo ... onocoque-1
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

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Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Nov 11 2016 5:15am

The WinterFun
Prototype fabrication https://www.facebook.com/3dflux

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E-Chopper   10 W

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Joined: Feb 10 2016 5:39am
Location: Lower Austria
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Re: Electric "tough bike"

Post by E-Chopper » Nov 11 2016 6:25am

Nice Ride ! it is always cool to follow a tread like this from the first raw Alu-Plate to a finished Bike !!!

Greetings
Martin
"Thunder is good,Thunder is impressive;
but it is Lightning that does the work !
-Mark Twain

vax   100 W

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Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Nov 11 2016 5:23pm

Thanks.
In meantime, we built this black chopper featured on video. It's actually Yamaha Dt125r enduro bike. Or was. 72V 40Ah LiFePO battery, 100A sinewave controller, 13' scooter hub motor. It doesnt even get warm, actually the batteries are limiting factor, they tend to sag under power.
It's very comfortable - yamaha link rear suspension with longer swingarm. 110km range etc
_20161112_002132.JPG
Prototype fabrication https://www.facebook.com/3dflux

vax   100 W

100 W
Posts: 214
Joined: Dec 14 2007 11:30am
Location: Keila, Estonia

Re: Electric "tough bike"

Post by vax » Mar 31 2017 2:17pm

And once agin, it's repair time.
I made real axle stand for the bike, which broke motor cable just where it enters the axle.
So, I have to rewire everything. Also I had some trouble with spokes, radial pattern wasn't strong enough for motor torque.
The new idea is one hole shifted pattern - all the spokes at one side are tilted on same direction, one hole further. Ath the other side, spokes are tilted to other side.
I believe it's also called Fallon Lacing
Image
Image
Situation rght now:
Image
Image
Prototype fabrication https://www.facebook.com/3dflux

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