Project Blue Smoke - Aprilia RS conversion

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Project Blue Smoke - Aprilia RS conversion

Post by -UP- » Apr 15, 2015 11:32 pm

Project Blue Smoke
Aprilia RS 125 conversion

I'm working on the electric motorcycle conversion, that I've been dreaming for a long time. The donor bike is Aprilia RS 125. This build is a hobby for me and I'll take my time to enjoy it.

You can follow also on Youtube and DriveTribe.
Forum_pic.jpg
Forum_pic.jpg (95.89 KiB) Viewed 2834 times
Project videos:
Introduction
Android dash
LED Indicators
PWM lights
Signal over operating voltage
The Frame
First ride
Track test
Battery Management System
Time-lapse build



First track test done with Revolt RV-160Pro, Kelly KBL96351E and Turnigy Multistar batteries.
Last edited by -UP- on Oct 14, 2017 12:27 am, edited 11 times in total.
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by 100volts+ » Apr 16, 2015 9:45 am

Subscribed
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Unlike puppets we have the possibility of stopping in our movements,
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Re: Project Blue Smoke - Aprilia RS conversion

Post by Ypedal » Apr 16, 2015 9:51 am

Right on... lol.. the video editing can be as big a challenge as the rest of the project . i know...

8)
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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » May 07, 2015 10:39 am



Some talk and comparison of LED indicators. I didn't have the original 21W/5W rear light to show on the video, but as seen LED's are way more efficient (0.76W/0.23W).

The next video will be about controlling the rear lights and indicators with quite unique system. At some point I'll also make a video of the headlight. If my vision works out, that's where the actual minimization of the 12V really comes from.
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » May 10, 2015 3:41 pm

I have successfully controlled the 24V H3 bulb with 72V PWM. Video coming later. Schematic below.

Image
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » May 15, 2015 2:06 am

PWM control of the headlights explained on the video:
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by agniusm » May 19, 2015 4:08 pm

What about is this?

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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » May 20, 2015 3:09 pm

agniusm wrote:What about is this?
What do you mean?
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by agniusm » May 21, 2015 2:46 am

You stated that you started the conversion but all i can see are some videos with leds and bulbs. No specs, motor, battery, controller planned on the install, photos of the actual bike and work on the bike.
BTW i like the bike farting blue smoke on the renderings :D

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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » May 21, 2015 4:19 am

Yeah, I haven't yet found the motor&controller that would fit on the project and on my budjet. I was thinking about the Motenergy ME0913, but it's a bit heavy and I haven't find controller to fit the specs. I've been asking about a used LEM-200 motor on another forum, but I'm still waiting for more info about it.

Meanwhile I'm playing around with electronics on the bike. My goal is to basically rebuilt the whole 12V system of the bike. As said, this is a great hobby project to combine my interests in electronics and motorcycles.

I actually don't have a garage to work on the bike, which is currently located at my parents house 80 miles away. Once I got the motor and controller, I try to spend some weekends working on the bike. And this will be a long term project anyway.

All suggestions for the motor&controller combo are appreciated. I'm looking for European dealers.
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB


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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » May 21, 2015 5:22 am

Would it be possible to make a custom shaft to lock two Revolt motors together? Then add extra bearing next to the sprocket. Should this kind of setup be controlled with one or two controllers? If controlled with one, how should it be wired?

Edit: found the answer from another topic:
Jeremy Harris wrote: Provided that both motors are mechanically kept in sync, with the rotors in identical positions relative to their stators, then yes, it will work. The problems are:

1. Getting the rotors aligned. This needs to be better than just doing it mechanically, as there's no assurance with a lot of motors that the stators are at the same angle relative to the mounting plate. One way to do it is to put DC at a limited current (may be a few amps) through the same winding on each stator, with the motors not mechanically connected. The rotors will lock at an angular position that is where you want to connect them together.

2. The other problem is that the motor apparent winding resistance will be halved, as far as the controller is concerned, so the controller will need to be able to deliver enough current. The good news is that the motor apparent inductance will double, giving the controller an easier time.

You only need Halls on one motor, as you've already worked out. I'm not sure whether a chain will be accurate enough to make the two motors run smoothly, unless it's pretty tight, when it might well have a high wear rate and be noisy. A toothed belt might be better, or better still try and mechanically lock the shafts together as one.
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by riba2233 » May 21, 2015 6:27 am

It's better to use two smaller controller, too many potential issues.

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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » May 24, 2015 12:28 pm

I contacted Revolt and they could make a custom shaft for two motors. Still I'm not sure how well this would work out.

I'm drifting back to Motenergy ME0913 with Kelly. ME1304 with Sevcon would be nice, too, but the programming of it seems too difficult.

Then there's the simple choice of brushed LEM-200..

I guess I'll think this a week or two and then order the motor and the controller.
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » May 25, 2015 9:23 am

The dual Revolt plan is now ditched and I have much better one. Revolt RV-160 Pro. I have to say that the customer support on Revolt is excellent!

Another thing that I just realized is that my Aprilia is registered on July 2003. On June 2003 there was a legislation implemented that requires EMC certificate for all the electronic components on the bike. I haven't contacted the inspection station yet, but this probably means that I must get an older frame. Luckily these old Aprilias aren't too expensive. I can still use the current bike to design the component mounts etc. and then take some spare parts for the other bike. I'll register the bike earliest next year, so this isn't a immediate issue.
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by netyello » May 26, 2015 3:20 pm

I have the ME0913 motor and using the 150v Sabvoton controller with it. It is a very capable controller than the kellys and it is customizable like the sevcons but at half the price. Others might be able to chime in with better experience with sabvoton, but I feel that the ME0913 and Sabvoton go hand in hand.

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Re: Project Blue Smoke - Aprilia RS conversion

Post by riba2233 » May 26, 2015 3:26 pm

Maybe a bit underpowered for 0913, 0907 would be lighter.

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Re: Project Blue Smoke - Aprilia RS conversion

Post by fellow » May 27, 2015 9:09 am

Loved the videos! Here are the controller suggestions:

1. VEC500-72 72V, 150A, 500A phase current. Dimensions:200*190*58mm (3.2kg). Price USD598 http://goldenmotor.com/
Image

2. Sensitron SMCV6 is probably more expensive. It is FOC controller, but you have to increse the voltage in that case. http://www.directindustry.com/prod/sens ... 90824.html
Image
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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » Jun 02, 2015 2:47 pm

That Golden motor controller would have been interesting as well, but I decided to get Kelly.

I ordered the controller and I'm waiting for the production of the RV-160 to start. Meanwhile, one more electronics video:

You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by riba2233 » Jun 02, 2015 3:00 pm

Nice controller/motor choice! What is kelly model?

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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » Jun 02, 2015 3:10 pm

KBL96351E

I'm not sure yet what battery I'll have so I decided it's better to get something 96V compatible, since the motor can handle that as well.
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by riba2233 » Jun 02, 2015 3:20 pm

Good thinking, it's better to give motor higher rpm (or as high voltage as possible), you get more power.

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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » Aug 12, 2015 5:39 am

Still 1-2 weeks until I can order the Revolt. Meanwhile some video update, although I haven't work on this much on summer.
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by -UP- » Sep 09, 2015 1:37 pm

Image

I got the Revolt RV-160Pro. Next step is to build the mount and try to get the wiring done.
You can find the Project Blue Smoke on Youtube, Tumblr and D_TRB

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Re: Project Blue Smoke - Aprilia RS conversion

Post by Emoto » Sep 09, 2015 2:33 pm

Good news, what version 160 is this short or standard
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