Hi, here I'll be posting progress of my electric motorcycle build.
I'll keep the whole build in one post, and discussions will be in posts below
In October 2017 I bought a used Cagiva Supercity 50, which is technically a moped, so it I can ride it with a driver's licence for a car.
-24 kg
Making sure a Heinzman PMS 120 will fit. It's a synchronous motor used in Brammo Enertia
Motor arrived in January 2018.
[youtube]5ZXKGdw3M3k[/youtube]
tested the motor by connecting it to my electric bicycle
Tested sin/cos sensor with the oscilloscope, forgot to take signal pic, but everything works fine.
Bought used Sevcon Gen4 Size 2, had to open it for fun
Designed a motor mount using Solidworks and tested dimensions using 3D printer. Printing with low infill and no faces to save on time and material on first tries.
A millimeter off on one hole, not bad for the first try considering I have no CAD of chassis because it's a 20yr old bike.
Did some quick stress analysis on motor and motor mount because of small front sprocket. Smaller sprocket leads to bigger force on shaft, plus the sprocket is near the end of the shaft ,so combined, it is very "ugly" loaded. Results reveal that shaft really is most critical part, but it is still 2,5 times stronger than ideally required.
Some weight reduction on motor mount. Colours are scaled down, so orange (almost highest stress) is still 4.5 times stronger than ideally required
(March 2018)
Front sprockets arrived, need to change inner diameter and make a keyway.
There are always some "nice" surprises when buying used stuff. I can only guess if previous owner had chain snap that resulted in this, but there are no marks on swingarm. It's a very rare and old bike, but fortunately I found a wheel in good condition in Austria, 40€ shipped, so that all could have end up a lot worse. Not mentioning it could have broke mid ridding.
Also did some quick FEM on rear sprocket just to make sure it's all ok.View attachment 15
(April 2018)
Sent a dxf. files for laser cutting sheet metal for battery boxes, rear sprocket and motor mounts.
Also changed the fork seals and added oil. Both fork sides were without oil, and one for seal was in pretty bad shape
I got tire mounted to new wheel too.
(May 2018)
Also connected the motor and the controller. Had a few minor errors like encoders, pre-charge circuit and temperature sensor, but fixed them pretty easily. Now I have no errors when powering up the Sevcon but it starts blinking 10 times after 5 seconds of solid green which means it is in "pre-operational" state and I should use DVT (sevcon software) with IXXAT USB/CAN cable to set it in operational state. I found the software, but cable is pretty expensive.
Some good guy from local selling site offered to borrow me a IXXAT USB-to-CAN cable for free.
IXXAT cable sees CAN communication ok, but unfortunately Sevcon DVT software doesn't recognize it :/
I think I'm gonna use my bicycle's controller for registration and tame a Sevcon some other time.
Also laser cutted parts arrived
I did some stupid mistake. Wanted fo motor to be in line with swingarm, so that chain doesn't come loose with suspension travel, but overlooked a fact that chassys part is in the way. New motor mount is on the way, but now chain is going to get loose when suspension is compressed. Gonna need a chain tensioner.
I'll keep the whole build in one post, and discussions will be in posts below
In October 2017 I bought a used Cagiva Supercity 50, which is technically a moped, so it I can ride it with a driver's licence for a car.
-24 kg
Making sure a Heinzman PMS 120 will fit. It's a synchronous motor used in Brammo Enertia
Motor arrived in January 2018.
[youtube]5ZXKGdw3M3k[/youtube]
tested the motor by connecting it to my electric bicycle
Tested sin/cos sensor with the oscilloscope, forgot to take signal pic, but everything works fine.Bought used Sevcon Gen4 Size 2, had to open it for fun
Designed a motor mount using Solidworks and tested dimensions using 3D printer. Printing with low infill and no faces to save on time and material on first tries.
A millimeter off on one hole, not bad for the first try considering I have no CAD of chassis because it's a 20yr old bike.
Did some quick stress analysis on motor and motor mount because of small front sprocket. Smaller sprocket leads to bigger force on shaft, plus the sprocket is near the end of the shaft ,so combined, it is very "ugly" loaded. Results reveal that shaft really is most critical part, but it is still 2,5 times stronger than ideally required.
Some weight reduction on motor mount. Colours are scaled down, so orange (almost highest stress) is still 4.5 times stronger than ideally required
(March 2018)
Front sprockets arrived, need to change inner diameter and make a keyway.
There are always some "nice" surprises when buying used stuff. I can only guess if previous owner had chain snap that resulted in this, but there are no marks on swingarm. It's a very rare and old bike, but fortunately I found a wheel in good condition in Austria, 40€ shipped, so that all could have end up a lot worse. Not mentioning it could have broke mid ridding.
Also did some quick FEM on rear sprocket just to make sure it's all ok.View attachment 15
(April 2018)
Sent a dxf. files for laser cutting sheet metal for battery boxes, rear sprocket and motor mounts.
Also changed the fork seals and added oil. Both fork sides were without oil, and one for seal was in pretty bad shape
I got tire mounted to new wheel too.
(May 2018)
Also connected the motor and the controller. Had a few minor errors like encoders, pre-charge circuit and temperature sensor, but fixed them pretty easily. Now I have no errors when powering up the Sevcon but it starts blinking 10 times after 5 seconds of solid green which means it is in "pre-operational" state and I should use DVT (sevcon software) with IXXAT USB/CAN cable to set it in operational state. I found the software, but cable is pretty expensive.
Some good guy from local selling site offered to borrow me a IXXAT USB-to-CAN cable for free.
IXXAT cable sees CAN communication ok, but unfortunately Sevcon DVT software doesn't recognize it :/
I think I'm gonna use my bicycle's controller for registration and tame a Sevcon some other time.
Also laser cutted parts arrived
I did some stupid mistake. Wanted fo motor to be in line with swingarm, so that chain doesn't come loose with suspension travel, but overlooked a fact that chassys part is in the way. New motor mount is on the way, but now chain is going to get loose when suspension is compressed. Gonna need a chain tensioner.
preaty loose.
