10kW stand-up scooter with air suspension

[alex_2d]

I want to tell the story of the creation of my stand-up scooter "VOSTOK 1"

My acquaintance with electric transport began with Pat Rover.For a year of use, everything broke that could break. The result was this:

Having made the most of what is, but not getting the desired result, I decided to make my project. The experience allowed me to determine what I want from the scooter:
1. Reliability (10,000 km without repair)
2. Power (5000W)
3. High mileage (~100km)
4. Comfort (Air suspension)
5. Manageability


After 3 months of persistent design and selection of components, it turned out:

According to calculations, the frame must withstand 1000kg of static load. All main parts are made from sheets and plates of Duralumin 2024, the power components - the titanium tube (20X2, 12x1.5)
Front and rear suspension stroke 140mm
Battery LiFePo4 - 24s3p 36AH
DD-800W 60V (stok)
Nucular electronics kit 12F - 5000W
Weight ~ 45kg

Production started with the rear suspension

to be Continued...

[fechter]

Looks great so far...

What motor are you going to use? You may want to use two motors to get that much power.

[Emoto]

EPIC !!! , i still havent decided on my motor yet. as its a reduction build , i can see why you chose that motor.

[TilmanBaumann]

Respect for before and after situation

[alex_2d]

Thanks guys, very nice!

What motor are you going to use? You may want to use two motors to get that much power.

I want to get out of the motor 60v800w, who is in the photo above, 5-7 kW continuous load. 2WD concept in a stand-up scooter conditions, I don't like in principle. I don't want to lose power every time the front wheel comes off the ground. And it happens all the time :) I don't want to Increase the outer diameter of the wheel either. It's the stand-up scooter, not a motorcycle. I plan not to go beyond 11".

[alex_2d]

Okay, back to the project. From the beautiful sleeves of carbon had to give up... They crunch when they drive. Replaced by duralumin:)
For tests, the rear suspension was installed on the remains of RetRower. In General, it works exactly as expected, but the pressure in the shock absorber is already 150psi. Well, I ordered shock absorbers with a stock, one is clearly not enough. Here is a short video from the first tests:

[fechter]

The suspension looks like it's really doing its job. Also looks like you really need it around there. I thought the roads here were bad...

[TilmanBaumann]

Lovely build. Almost what I wanted to build for a long time.
I like to build a electric Plankalkül.
http://bodenstandig.de/plankalkul/video-de.html
Yours is pretty much there, slight modification to the steering...

[alex_2d]

Resume :) With the production of decks had to tinker. CNC milling and assembly took about 40 hours. The side pieces were made of duralumin plate 16 mm. Upper and lower platform of duralumin sheet 3mm.
The process of milling the side elements of the deck:

Everything fell into place perfectly:

Make a groove for cover:

Front and rear walls of the deck are securely connected between the two titanium tubes 12x1.5mm

With the rear suspension, it looks like this:

[fechter]

CNC porn.

I like the huge pile of swarf on the floor. That's going to be one really nice looking scooter.

[TilmanBaumann]

No kidding. That diamond pattern is just sex on a stick.

[alex_2d]

Then I will continue to please fans of perversions ^_^
Headtube. 2x roller bearings static load rating 44 kN

013.jpg (337.57 KiB) Viewed 5457 times

Here parts for a gooseneck and the front suspension

The headtube is connected to the gooseneck on this principle:

The build looks pretty funny =)

For tightness of the deck, made of silicone seal

And finally, the whole mechanical assembly

[icherouveim]

Congratulations! You've done a great job, it looks like professional from the factory! But why two shocks at the back and only one at the front? Are you planning to be at the back the most of the time?

[alex_2d]

Thank you, you flatter me =) One shock in the front - my mistake. This is my first project and I have never worked on the development of scooters. In the end, I completely redid the front suspension, but first things first :)

[alex_2d]

The next stage is electronics:

3.jpg (197.07 KiB) Viewed 5407 times

Battery - LiFePo4 24s3p - 72v\36AH
Ant bms - 300A
Nucular electronics kit
dc\dc

Readey to start :-)

At the beginning nucular controller had only square wave control. Therefore, the maximum speed was limited to 38kmh.
The suspension exceeded all expectations! But it became obvious that one shock absorber in the front will not be enough. For the desired stiffness had to pump 180psi...
One of the first races:

Off-road uphill:

The sound on the square wave, as if someone all the way tormented by the cat :-D
On video the rise order 18%, the average the speed 20km\h. Position gas 45%. Average phase current 30A, 60A peak. Just happened to drive 3km and the motor filled with oil warmed to 110 degrees Celsius...

[fechter]

Looks great.

A sine wave controller will make it almost silent. If you get one with field weakening, you can get a higher top speed depending on load.

Any estimate on the total weight?

Are you compressing the cells?

[alex_2d]

Any estimate on the total weight?

Approximately 47kg

Are you compressing the cells?

No, of course :) There is a distance of 2 mm between the battery and all the inner walls of the deck. This distance is filled with polystyrene foam.


Just a couple of weeks after the tests started, a new firmware was released for the Nucular controller. With FOC, but without field weakening. After that, I decided to learn how to rewind the motor to achieve the desired characteristics. The second time it happened :)
Factory stator: winding the number of turns in a stator winding - 9, wire section 1 mm2.
After rewind: - turns - 7 \ 1.7 mm2

5.1.jpeg (228.97 KiB) Viewed 5398 times

6.jpeg (171.72 KiB) Viewed 5398 times

The maximum speed increased up to 54 kmh. Motor power increased to phase 40A continuous and 80A peak. The battery current 40A.

[alex_2d]

Impressions from the management of this scooter is difficult to describe in words...Delight from every trip!
I had my doubts about such small wheels (11"). But the 9-inch-high curb was an easy task.

You can easily climb any slope (steeper than 67% I have not yet found)

And in general, you can not particularly look at the road, and just choose the direction

[alex_2d]

After the first 1000km I got used to the scooter and the power was not enough... But it was impossible to increase the power of the motor without additional heat dissipation.
It was decided to make the radiator cap.

3.jpeg (21.58 KiB) Viewed 5379 times

Did a little maintenance. Rather, it was just an inspection, as there were no problems in the work. Replaced the front brake with hydraulic. Too much speed and weight for a mechanical brake.

6.jpeg (20.05 KiB) Viewed 5379 times

9.jpeg (95.7 KiB) Viewed 5379 times

After installing the radiator, the temperature of the motor, under the same loads, fell by 12-15 degrees. This allowed to raise the current by 5A, remaining within the range of 110 degrees.

[icherouveim]

So can you ride full speed for example for 50km without to overheat the motor?
Does it stop well with the new hydraulic brake?
I can see you've already scratched it at the bottom a little bit, Do you go off-road a lot or is very low?

[alex_2d]

Joy was short-lived... 2300km and the rear tire died...

And these are dead, front tires and cheap, сhinese bearings

Front bearings replaced by german.
To order the same back tire there was no desire because it is a piece of shit=/ Decided to solve the problem fundamentally, to alter the motor under a go-kart tire.
At the same time to solve the problem of heat removal

For these purposes, bought a set of tires for karting

[alex_2d]

So can you ride full speed for example for 50km without to overheat the motor?

On horizontal roads, at a speed of 50kmh, the temperature of the motor 60-65 degrees. Here is only horizontal roads in my city of very little

Does it stop well with the new hydraulic brake?

Now, if desired, you can lock the front wheel. Braking efficiency has increased many times!

I can see you've already scratched it at the bottom a little bit, Do you go off-road a lot or is very low?

Clearance 200 mm. Often go off-road, and I do not like to touch the ground with my feet =)

[LeftieBiker]

I'm not especially interested in this kind of scooter, but this one is so beautiful, so fast, so well built, that I fantasize about riding one!

[alex_2d]

Remaking the motor.
The first thing you need to remove all unnecessary. The factory tire has a rim diameter of 5.5". Tire for go kart 5".

Make two new motor covers

The result was a fun keg =)

Wearing a tire was very difficult... The landing diameter of the tire 122mm. Minimum diameter of the motor, which turned out to do without loss of strength - 128mm

But the result was very nice :)

[tomjasz]

Wow! Nice, very nice indeed!