drc wrote: ↑
Nov 13 2018 10:39am
So I have had a busy few days with all the items and planned my approach with the build of this scooter. I started with the wiring as there is a limited amount of space available for the wiring as there will be a 20s lipo pack, bms 12v dc to dc converter and lots of wires to sort out. So I figured all the wiring and soldered all the connection to make it solid.
after testing everything I rapped up the wires. Next was to mount the controller , now as this potentiality going to generate more heat than the standard controller, so I decided to screw the heat sinks directly to a ½ aluminium flat bar. All ridges have been leveled and I used thermal past to bolt it to the inside of the battery box. I velcro’ed the dc-dc converter to the side and built up the battery pack to maximize space. The battery is made up of 20s mulitstar packs soldered together and linked up to a Bluetooth smart BMS.
So a big tick. That’s the wiring and plumbing done. In addition to this the PV Bluetooth controller has a heat sensor build in ( cheers EG) so I can monitor its temp the PV app and I also planned to put one inside the c80100 motor.
So for switches I have the following. A main key switch to turn on the controller
a separate switch/feed to the dc to dc control as I want all the power to run at 12v and not 84v.
Front and rear led indicators with a toggle switch
Rear stop and side lights
LED head light
and a 3 speed switch to the controller which a can fully tweak with the PV app. I have gone with 1: slow speed and medium torque 2: medium/high speed and 3: high torque and full speed and full torque. I have not yet worked my confidence up to using the speed boost (field weakening) as it should be plenty fast enough.
So the battery BMS is fully programmable via phone or laptop and the BMS has temp sensors wired in for good measure.
So that is just about it with the wiring, now time for making a mounting plate for the motor and stripping the rear end down so I can build it up.
Now a photo speaks a thousand works so I won’t go on to much but the drive train is a 219 chain running a 17t motor sprocket and 72t rear kart gear, mounted to the adapter plate then mounted to the wheel. These will all but tensioned by a custom chain tensioner I have made. I will let the photos help explain when they come.
So after a lot of thinking cutting, bolting, drilling, unbolting, checking, bolting and more thinking I have finished to build.
Next is the first test ride: so turned it all on and triple checked all the settings and set it to low speed. The soft start kicked in and I was off. As I did lots of bench testing on the drive train I knew it was al lined up perfectly and all would be good but there is still the air of “what if it goes wrong and I fall off” . So I took it slow down the road and released the throttle to be greeted by the regen!
I thought this will take some getting used to but no the less carried on. Opened it up a little more only to see the speedo was reading 40 mph . “Hang on this is jogging speed of 40mph!” So more fettling with the settings and using another GPS device to check how close I was to the actual speed. Well that is sorted out now and I know up to 20mph it is bang on accurate.
So after checking the 160mm discs where good for some hard braking and that there were no problems with the running gear I switched to speed option 2 and went for a spin on a wet and dark country lanes. Well what can I say, I weight 20 odd stone and the thing pulls strong up to 36/38mph and there was more to go! but I am still building my confidence! I was shaking when I pulled over as I was so excited just like the big kid I am! so onward I thought then why not push the torque up to full and see what hard acceleration feels like.
All I can say is it feels good, very good! After about 5 miles of giving it some stick in that setting I got home in a very happy mood and noticed the temperature gauge for the controller was only showing 27C ( my heat sinking idea worked out well then) and the motor crept up to 60C ( the probe is mounted as close as I could get it to the winding's without taking it to bits).
So all in all I am very happy with the build and how it runs and I want to say a personal thank you to Richard (Electric God) for all your help on this project. You have built me a great motor and controller and have always been there when I got stuck. You have been very patent and I think its been a great journey and I have picked up a good friend.
Anyway enough of that ! There will be more for me to do as I am never happy and this is why I love projects like this………………… oh anyone looking for a 1600w boma motor and controller a couple of different pinions and gears? Oh I have cut most of the connectors from the controller off but it works fine.
photos added later