EKartGo Project

Electric cars, trucks, ATVs, NEVs - things bigger than a motorcycle.
Upperfoot   100 W

100 W
Posts: 122
Joined: Jan 07 2018 2:42pm

Re: EKartGo Project

Post by Upperfoot » Jan 08 2021 7:23pm

I would try out those cell holders you can put together like logo, I personally use the ones from https://e-bikestuff.com/en/11-cell-holders

thepronghorn   1 kW

1 kW
Posts: 305
Joined: Mar 27 2011 8:07pm
Location: Bay Area, California

Re: EKartGo Project

Post by thepronghorn » Jan 09 2021 3:35am

Where did you get the printed parts from? That looks pretty bad. I have a printer myself, but I've thought about using online services for some bigger parts that I want, but that quality does not inspire confidence.

User avatar
hallkbrdz   100 W

100 W
Posts: 133
Joined: Mar 24 2018 1:47pm
Location: Edmond, OK USA

Re: EKartGo Project

Post by hallkbrdz » Jan 09 2021 7:57am

thepronghorn wrote:
Jan 09 2021 3:35am
Where did you get the printed parts from?
I went though Craftcloud, and the actual printer was DTEV LLC in Vero Beach, FL. I can't believe they shipped something so poor in quality.

The reason I am making my own holders is to allow the cells to go end to end and eliminate welding. Placing them end to end saves weight in copper bus bar material since only the final positive and negative ends need to handle the full current. The rest just need to carry 1/10 that amount with my 42SP10 battery.

I have already revised this design with some improvements and I am seriously looking at buying a Prusa I3 MK3S+ with the multi-material option to fill voids after this experience. Once I get this process down I may go into the high-current battery business.

User avatar
hallkbrdz   100 W

100 W
Posts: 133
Joined: Mar 24 2018 1:47pm
Location: Edmond, OK USA

Re: EKartGo Project

Post by hallkbrdz » Feb 15 2021 4:24pm

Update:

Back on 2 Feb I ordered new rev 6 battery parts in ABS. I would prefer nylon, but until I build a printer to make them myself that is just too costly due to the small number of places that can create them in that material. From the looks of i-Solids in Texas, I think this round will be better than the last one.

Here's some photos of the new parts they sent me after printing (I hope to get them tomorrow or Wednesday, weather depending).
batteryparts1.jpg
batteryparts1.jpg (51.52 KiB) Viewed 191 times
batteryparts4.jpg
batteryparts4.jpg (140.61 KiB) Viewed 191 times
batteryparts3.jpg
batteryparts3.jpg (100.63 KiB) Viewed 191 times
batteryparts2.jpg
batteryparts2.jpg (64.15 KiB) Viewed 191 times
On the same day I received an email from DHX Machines with the CAD file for the new Peregrine alpha-test motors. So hopefully they will be out for testing sooner than later. Yes!

I then worked on the motor support. I think this will prove to be a good and flexible design. There were lots of things to consider for this torque monster (estimated to be about 120Nm, 89ft. lb) to keep from bending the frame. For reference, an IAME X30 Super Shifter Spec. USA 175cc only delivers 27 Nm, 19.9ft. lb!
Motor Frame.jpeg
Motor Frame.jpeg (246.93 KiB) Viewed 191 times
Now I'm working on the controller mount. I think something like this will work with ducting added to the bottom to draw cool air across the heat sink. If not, I'll get a water cooling plate for it and upgrade to a double pass radiator.
Controller mount.jpeg
Controller mount.jpeg (271.98 KiB) Viewed 191 times

User avatar
hallkbrdz   100 W

100 W
Posts: 133
Joined: Mar 24 2018 1:47pm
Location: Edmond, OK USA

Re: EKartGo Project

Post by hallkbrdz » Feb 20 2021 11:14pm

Build progress...

3D printed parts in hand, look great. Only issue is the dimensions are slight smaller due to ABS shrinkage. So I'm having to bore and smooth the cell connections out, and slightly enlarge the copper plate paths. Certainly not show stoppers by any means. Next battery will have revised designed to allow more space for this issue. FDM 3D printing is somewhat of an art vs CNC.

Kelly bluetooth and various connectors ordered. The bluetooth will allow connection to a laptop or Android tablet for programming.

Motor coolant pump ordered. It is a Toyota Prius inverter pump and will run off the tool battery.

Orion2 BMS and battery charger will be ordered Monday.

I plan to have a Battery Day by the end of the month. There will be a scheduled live event assembling it, as it should not take that long using this new weldless method. Stay tuned!

Here is the current working idea for the controller coolant duct and possible placement for the water pump.
Rear controller duct.jpeg
Rear controller duct.jpeg (298.84 KiB) Viewed 152 times

User avatar
hallkbrdz   100 W

100 W
Posts: 133
Joined: Mar 24 2018 1:47pm
Location: Edmond, OK USA

Re: EKartGo Project

Post by hallkbrdz » Mar 04 2021 1:43pm

Here is the current "simplified" wiring diagram for the system. Doesn't even show all the cell tap wires! Wire management is key.
20210304 Electrical SimpleBatt - Orion.png
20210304 Electrical SimpleBatt - Orion.png (1.62 MiB) Viewed 43 times
Last edited by hallkbrdz on Mar 04 2021 9:44pm, edited 1 time in total.

User avatar
hallkbrdz   100 W

100 W
Posts: 133
Joined: Mar 24 2018 1:47pm
Location: Edmond, OK USA

Re: EKartGo Project

Post by hallkbrdz » Mar 04 2021 6:28pm

Top tip: To smooth out 18650 holes on the 3D printed part, I found a 23/32" drill bit works pretty good. The 47/64" one I used previously made the holes slightly loose.

User avatar
hallkbrdz   100 W

100 W
Posts: 133
Joined: Mar 24 2018 1:47pm
Location: Edmond, OK USA

Re: EKartGo Project

Post by hallkbrdz » Mar 06 2021 11:49am

Rendering showing that battery configuration in it's packaging. Four variable speed BMS controlled 120mm fans for cooling.
20210306_kart_w_new_battery.jpg.jpeg
20210306_kart_w_new_battery.jpg.jpeg (280.53 KiB) Viewed 23 times

Post Reply