...A new one! [low-cost dirt bike] -- second test video

Hey guys, after the first tests it's time to upgrade a bit the hardware side to correct some little problems.

new version has a more efficient voltage step-down side, better electromagnetic compatibility and smaller dimensions.
I can now close it inside a commercial box.

12%2520-%25201.jpg


12%2520-%25202.jpg
 
you know.....I'm with whiplash.....can't wait to see your device working, hopefully on my bike too.... :mrgreen:
Can't wait to see your "dry" gearbox working, even if, you know, I'm skeptic about its reliability, but As from your signature......you could change my opinion easier than the facts.... :mrgreen:
would be glad to support you in any way I can.....remember it.
Cheers
 
panurge said:
you know.....I'm with whiplash.....can't wait to see your device working, hopefully on my bike too.... :mrgreen:
Can't wait to see your "dry" gearbox working, even if, you know, I'm skeptic about its reliability, but As from your signature......you could change my opinion easier than the facts.... :mrgreen:
would be glad to support you in any way I can.....remember it.
Cheers

Thanks a lot Lorenzo, I really appreciate your support (and obviously the support of the entire forum)!
 
Hey guys!

pretty new version of the Smart Bike Controller! :D

13+-+1


Unfortunately I had no 10AWG wire at home, so I had to use 14AWG wire for tests. I'll change it tomorrow.
 
...and another updated version is here!

I made big changes in the voltage step-down DC-DC converter, I'm using a switching now in order to achieve lower power consumption and higher power, it can handle up to 3A now. Additionally, the controller can now be used with voltages from 7V to 60V without any changes.

I then refined the low-pass filtering for the current sensor, in order to get more stable and precise current sensing.

SmartBikeController_2.1_adj.png
 
Great job! Can we get a rundown on all the features as of now? Any idea on cost for these?
 
Actually, I haven't planned how/when/why to sell it yet.
At the moment I'm focused on testing it and upgrading it, then when I'll reach a perfect hardware design (in terms of reliability, performances and dimensions) I'd like to make 2/3 "developer editions" and give them for free to someone to help me correcting bugs, refining software and expand functions.
Then, maybe, I'll think about selling it (the cost for this controller could be lower than his "famous" cousin...). But I'll need a find a fund for that.

Anyway, what is it?

This is a "smart" controller for RC vehicles, basically a bridge from a pot throttle and a commercial ESC.
I'm saying smart because of the other functions it can handle.
First of all, it has a 128x64 graphic LCD with a built in user interface, you can interact with just two waterproof pushbuttons.
Via this UI you can either access all the data coming from the controller then set all the parameters you need.
At the moment, the parameters it can acquire are:

- Direct and inverse current (-160A to 160A)
- Battery voltage (7V to 60V)
- Speed from hall sensor or reed switch
- Throttle position
- 2 Temperatures
- 1 additional digital I/O (pedelec?)

Then what can it control, at the moment:

- ESC control
- 2 servo PWM control
- 1 internal 10A relay at supply voltage (let's think about vehicle's lights)
- 1 internal DC-DC converter, 5V @2A

The key of this device is that all this features are handled via a simple, well-known and opensouce software (Arduino).
This let everyone customize it as he need, and build all the specific specific functions you need.

For example, my UI can let me change gears (controlling the two servos) using the UP/DOWN pushbuttons, or it can automatically increase a gear when the motor speed is too high AND the power is getting down, conversely it can decrease a gear if the motor is slowing down and power is growing (an hill).
Then I can choose how to "smooth down" the throttle input in real time, just changing the riding mode.
An additional feature I made is the "street legal mode", which basically let you accelerate only if you're moving your pedals and cuts the power up to 250W (maximum limit here in Italy). Obviously I can activate/deactivate this function just switching the riding mode.
I can read from the battery in terms of voltage, percentage and kilometers (or miles) left.
I can store the total travel of the bike, the travel since the last time battery has been recharged and the travel from the last power-on.
I can directly control the bike's lights just activating or deactivating an option in the riding menu. No other hardware switches are needed.
The controller automatically decreases power (and rises a warning) if the motor or the ESC is getting too hot, and helps me finding the maximum efficiency showing me the speed over power ratio.

This are the functions I made because I need them on my own bike, but you customiize it as you want.
Let's assume you don't need to control 2 servos, you can use that 2 connectors to add another hall sensor or reed switch (regen brake?), you just need to build up your own software feature.

In other words, a fully customizable controller. :wink:
 
Wow very impressive! Its only for RC motors then?
 
At the moment yes, but I'd really like to directly drive the motor in the future. It would open the way to many other interesting features.
But that's not a trivial task, so I prefer to have a stable base for the controller and then concentrate the development in the power stage.
Step by step :D
 
a little big update:

16c2zhe.jpg


The electronic controller is now really small using SMD components and double layer board.

I made some oder steps in the mechanics also, I'll upload new pics soon... 8)
 
Ciao Silvocross!!!!
cannot see the image... :(
I'm waiting keen for your progresses....And since I have an already working and relialble RC bike, and we live close (among the ES members, at least) , I would like to be a beta tester for your device if this could be of some help for your development and you plan to build up more than a single exemplar....
Looking forward....
 
Ciao Lorenzo!

I think now you can see the picture...
This is exams period for me, so it will take quite a bit to finish the controller but I'm at a good step.

I've got 10 of it, and for sure one is yours... :wink:

oh, I forgot to say that now this controller can control both an RC ESC (so via PWM output) and a standard electric vehicle regulator, nice feature!
 
silvocross said:
I've got 10 of it, and for sure one is yours... :wink:

oh, I forgot to say that now this controller can control both an RC ESC (so via PWM output) and a standard electric vehicle regulator, nice feature!
Woah! that's great!
And the e-bike controller feature was strongly needed if you planned an even small production.
You are the man!!!
 
Hello,

Realy nice work! ... I love your idea of an electronic shifting mecanism using rc servos.
In one of my builds I also developed a shifting mecahnism with an rc servo. The only difference is, taht it was controlled by a tourque sensor and a speed sensor.

So on you don't have to shift by hand and find the suitable gear for the right situation.

One idea of mine was also to measure the current consumtion of the motor to shift the gears. that would be a greate feture!

...Jacob
 
Thanks jack!
The controller already has the ability to switch gears both in automatic and manual mode.
For the automatic switch I'm sensing the current gradient, speed and throttle position.
 
Hello silvocross,

That's very fine! ... A great idea. I would also be excitet about some videos. Last year i also made my "automatic" transmittion. My system didn't measure the current gradient of the motor but I made a tourque sensor which also allowes to measure the ammount of tourqure just in pedal- mode!
Would also be great to use a tourque sensor in your bike

... Jakob
 
Here a brand new version of the smart bike controller:

IMG_20130728_213041.jpg


I then built a little wooden box to include the pushbuttons, when I'll have some aluminum in hands I can make something better.

IMG_20130731_145453-300x225.jpg


Then I finally mounted the controller, the LCD and the entire cover on the bike:

IMG_20130731_145518-300x225.jpg


IMG_20130731_145535-300x225.jpg


IMG_20130731_145601-300x225.jpg


And here a short video of all this stuff...

http://youtu.be/IwRjSz6Kaog
 
That is awsome, I know it is way too late for a suggestion but....

If you could run the battery balance tabs to it as well, maybe not to balance them but just to give a on screen display of say the state of balance, and disable the throttle if a cell/cells are below an adjustable amount ie 3.4v. I know it is possible to do this already with available balance boards, but what they dont do is give you a graphical display of what is going on.....it would be a lot quicker to view a screen and find that one of the cells is out.

Keep up the good work
Rodger
 
rodgah said:
That is awsome, I know it is way too late for a suggestion but....

If you could run the battery balance tabs to it as well, maybe not to balance them but just to give a on screen display of say the state of balance, and disable the throttle if a cell/cells are below an adjustable amount ie 3.4v. I know it is possible to do this already with available balance boards, but what they dont do is give you a graphical display of what is going on.....it would be a lot quicker to view a screen and find that one of the cells is out.

Keep up the good work
Rodger

Thanks Rodger,
Your idea is definitely not bad, and absolutely feasible.
thanks for the input, I still need to finish and test all the advanced features (i.e. bluetooth connection) but I think in the next hardware version I can easily add a cell monitoring feature.
I'm trying to imagine all the possible interesting features so, step by step, if possible I can try to implement them. :wink:
 
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