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  1. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    Update The main project is progressing well with the mechanical team using a 1 HP motor and another smaller motor (possibly NEMA 23 stepper) via a double differential steering gear box (tank steering). I just sent out for a CNC'd heatsink for an IP68 rated aluminum box to mount a RP5 and HAT...
  2. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    Please understand that the entire reason for this open source project in the mobility space is that the current "proven way" and "cost-effective way" is neither. Those right-angle motors such as the Chinese sample shown above, or simular AMT units used by many manufacturers, at 12 Nm (Chinese...
  3. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    I realize that, but other than for maybe the fold-up ones, there's no reason to do that any longer. It's just lazy old tech on the high-priced chairs. At least use in-line AC motors with a long-lasting planetary gearbox.
  4. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    Yes I understand the issue with tire diameter and torque. Optimally that 20" wheel would be made for 20x4 tires and have an ~18 inch motor, but it's pretty close. Advertised torque is a little less than required, but for short burts it might work.
  5. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    Yes I'm aware of those motor / gear units. Personally I'd avoid any brushed motor and 90 degree angled drive for this sort use in a new design. They require more maintenance than is necessary using larger direct drive axial 3 phase motors, along with having no regen for outdoor use. The swincar...
  6. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    So I spoke with Thomas and a member of his team today. Their design was much more complete that I they let on publicly. This first model uses 16 inch bicycle tires (kid bmx) on what I believe is a custom rim. The two front wheels are driven with a double differential that uses a 1KW motor for...
  7. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    This is what got me going down this interesting path. I have a scheduled call with Thomas on Saturday to discus some of these ideas.
  8. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    Here is a rough design mock-up for what I'm working on to arrange the mechanical items (ignore the correctly sized but crude seat and leg supports). Unlike a "normal" wheelchair, the large wheels are placed out front to allow it to climb obstacles that can be encountered in the city like this 6...
  9. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    Thanks for that, but at 80 nm of torque it's too weak. Not that it might do at least double that for a couple seconds, although with the added weight calculations show 180 nm will be required with no momentum. Since then, and with the goal of keeping it as light as possible, I've found that a...
  10. hallkbrdz

    Mobility use - 14" wheels and hub motors?

    I've starting to work on an open source design for a power chair (powered wheelchair), and one of the many design goals is to have reasonably sized front set of wheels so that it can climb up things like full-sized curbs. To do that you need a wheel more than twice the height of the obstacle...
  11. hallkbrdz

    HD truck EV with range extender

    F350-F550 size is what I'll be primarily targeting. Think service trucks for the oil field, or tow trucks. Severe duty stuff meant for commercial use with minimal downtime. Aim is about 1/2 the cost of a new vehicle, but using about 50% or less of the fuel for the same work. Potentially a...
  12. hallkbrdz

    HD truck EV with range extender

    Yesterday I put down a deposit on an heavy duty truck EV, with a range extender kit. Electric drivetrain with unlimited range for service trucks. Best of both worlds. I'm now looking for a shop to start to do these conversions commercially in the next year. Integration with the existing body...
  13. hallkbrdz

    Coil winders

    Winding good quality orthocycle coils on a rectangular form isn't easy, but I'm getting there...
  14. hallkbrdz

    Mid-sized Motors = Pathetic Choices

    Thanks, interested to see what it does under load.
  15. hallkbrdz

    Sotion MG138-F Watercooling 15/30kw PMSM motor

    Any updates on this?
  16. hallkbrdz

    Mid-sized Motors = Pathetic Choices

    DHX has high quality motors, but yes they are all water cooled. To get anything of that power density it will need to be water cooled as there isn't enough surface area without making the motor quite large to dissipate the heat with fins for even the continuous power rating. I think the P-20's...
  17. hallkbrdz

    Coil winders

    FYI, if you are interested, I'm documenting the evolution of this build on a reddit channel here: https://www.reddit.com/r/Coil_Winders/
  18. hallkbrdz

    Coil winders

    Update: Finding no good off-the-shelf solutions, I decided to build my own using an OpenBuilds C-Beam® XLarge Linear Actuator Bundle for the X axis with a standard 1.8 degree stepper motor, onto which is mounted the bobbin motor with another 1.8 degree stepper motor. These are driven with two...
  19. hallkbrdz

    Coil winders

    Thanks, although this leaves a lot to be desired in precision, at least based on the video referenced. The layers need to have evenly spaced turns so that alternating layers stack well (14 layers is my target). Using a feed tube drilled just slightly larger than the wire is what I plan to use...
  20. hallkbrdz

    Coil winders

    Anyone know of an automated winder that can: Wind coils on rectangular bobbins (good magnetic tension assembly) Wind orthocyclic coil layouts using offset layers I need to wind small coils with 28ga wire, 18 layers deep, on a bobbin 9mm wide, with a 11.6x27.5mm base. Winding orthocyclic coils...
  21. hallkbrdz

    jonescg's NEW electric racebike BUILD thread!

    That makes perfect sense and is something all racing organizations should require for HV systems to ensure worker safety to the greatest extent possible.
  22. hallkbrdz

    Laser cut silicon steel laminate?

    Yes. For the prototype design at the time with 24ga M19 C5 in stacks of 1 inch bonded with EB-548, in quantities of 100, it would be $109 each. I need 8 of those per motor. Of course the magnetics design has changed twice since then, with the newest iteration to show up this week for testing...
  23. hallkbrdz

    What FEA software do you use?

    I started with FEMM's 2.5D solution, but for what I'm trying to model I now realize I really need a true 3D solution. What magnetic FEA software are you using?
  24. hallkbrdz

    Core laminate insulation

    I looked at the CoronaDope, but it appears to be rather thick and brushed on. I also looked at double-stick kapton tape, but that makes for a rather thick insulator as well. I also considered just using metal etching primer which I think should work fine for ~50v peak. For this prototype POC I...
  25. hallkbrdz

    Core laminate insulation

    I need to insulate laminates to make prototype coil cores. I think this is my best bet to apply a thin layer quickly. What do you use? https://www.mcmaster.com/products/electrical-insulating-varnish/
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