Cyclone 1600w fixed in frame with a 3D printed holder.

[chupa]

Hi dear community. Today i showing my little project - ABS plastic holder for cyclone motor.
In January of this year I decided to make ebike on the basis of a cyclone 500w. I threw out default holder of a cyclone and printed new, for Cube AMS 100 frame.
This bike with plastic holder passed 3000 km and 1000 km passed in a 30`c heat in the Crimea within a month. In the Crimea I constantly rising in long hills. Several times protection against an overheat worked. Tests in a 30c heat is done. Plastic didn't melt, and the motor keeps as driven. No any backlashes and material aging within 6 months.
A week ago I modernized the bike and installed the new motor 1600w with Kelly controller which gives the capacity of 4.5 kw . Plastic holder perfectly holds in a big torque. below there is video where I testing my bike in mountains on a heat in the Crimea .
Sorry for my english.
Weight of holder - approx 300 gram.
Total bike weight (without batteries) - 19kg.
Batteries Li-Po 'Zippy compact 5000' 12s2p in a backpack - 2.8kg.
After upgrade motor to 1600w max speed 59kph(speed configure) or 48 (torque configure) ( power limited by kontroller - max 3kw)
Maximum torque - approx 230nm with speed configure and approx 300nm with torque config.

3D printed power port:

3D printed Flash holder on a handle bar.

Video: (Sorry. I speak only russian)

Up hill (approx 25 degree. length 3km) in a 30c heat with additional cargo 25kg. Test for my transmission and general test for plastic holder.
http://www.youtube.com/watch?v=k2PfAG_Xq8o


Other videos (testing in Crimea):
http://www.youtube.com/watch?v=uLQt-GQ3NPY
http://www.youtube.com/watch?v=4iAFGTzyUEg
http://www.youtube.com/watch?v=SNEhh2aoB_w
http://www.youtube.com/watch?v=vWy1bnsAtu0

Up hill approx 35-40 degree with 1600w cyclone motor(4.5kw in a peak)
http://www.youtube.com/watch?v=funGbIpYkMY

 

[savaoaknyc]

WOw
what a nice build.Really like it.In 2 weeks i am starting also my project, which is gonna be based on cyclone. You've mentioned speed and mountain transmissions.Are these new planetary gears or ???What is your average wattage while climbing 25, 30 % inclines??
Greets Sava

 

[chupa]

WOw
You've mentioned speed and mountain transmissions.Are these new planetary gears or ???

No no. I replace second pedal gear 52t with 32t.
With 52t - this is a speed config. With 32t - torque.

WOw
What is your average wattage while climbing 25, 30 % inclines??
Greets Sava

Motor 500w
On 25 degree - approx 19 wt hour on 1 km (without additional cargo 25 kg)
With cargo - approx 25wh on 1 km.

Motor 1600w - not tested.

My current transmission config for 1600w

I am not use default cyclone transmission.
Custom spider for race gears:

 

[Wishes]

Very nice work with the 3d printed bracket. Nice build

Wishes

 

[kfong]

Nice work. Looks very solid.

 

[cwah]

Incredible. Which 3d printer did you use to have so good results?

 

[bose]

Probably one of the cleanest builds on ES! Very well done. Everything looks well integrated, it makes me want to buy a 3D printer!

Your power port is very nice, what is the name of that connector?

 

[cwah]

And what 3d software did you use?

 

[chupa]

Your power port is very nice, what is the name of that connector?

This is a china no name connector. May be from microphone cable. It worked at the 500w cyclone perfectly within 5 months. But after upgrade to 1.6 kw the port burned down.
Now I use new power port with XT-90 connector:

 

[chupa]

And what 3d software did you use?

I use 'UP Plus' 3D printer with russian Compass 3D for modeling.


Today i finished my custom throttle with printed two flashlight switches for left hand. This throttle is a modernized left gear bike switcher.

Kelly controller mounted under motor with printed holder.

 

[1KW]

WOW, how much for one of those mounts..Sure you could sell a bunch on here.

 

[Whiplash]

Beautiful work! I love the printed pieces! So very clean! Does the plastic help to quiet the motor?? I would imagine it would help..

 

[chupa]

Beautiful work! I love the printed pieces! So very clean! Does the plastic help to quiet the motor?? I would imagine it would help..

To quiet the motor?? How it ?

 

[Whiplash]

I just thought it would help with some resonance...

 

[chupa]

I just thought it would help with some resonance...

No no. the motor sound similar with a metal holder.
The sound depends on density of greasing in a reducer and level of wear of gears .

 

[cwah]

Hello Chupa,

I've found it cost more than 2000USD without shipping... it's way too much for me. Can I use this one instead?
http://www.aliexpress.com/item/3d-printer-duplicator-4-new-version-dual-extruder-ABS-PLA/987254984.html

Also, couldn't find your 3D software on google. Some friends recommended me autoscad:
http://www.openscad.org/

What do you think of this?

 

[justlooking]

Hello Chupa,

I've found it cost more than 2000USD without shipping... it's way too much for me. Can I use this one instead?
http://www.aliexpress.com/item/3d-printer-duplicator-4-new-version-dual-extruder-ABS-PLA/987254984.html

Also, couldn't find your 3D software on google. Some friends recommended me autoscad:
http://www.openscad.org/

What do you think of this?

if you are in the uk m8. maplings do a 3d printer, the cheep one you have to put together though

 

[chupa]

Hello Chupa,

I've found it cost more than 2000USD without shipping... it's way too much for me. Can I use this one instead?
http://www.aliexpress.com/item/3d-printer-duplicator-4-new-version-dual-extruder-ABS-PLA/987254984.html

Also, couldn't find your 3D software on google. Some friends recommended me autoscad:
http://www.openscad.org/

What do you think of this?

You can use any 3D modeling software. Like solidworks , kompass and etc, but printer should printing ABS plastic only !!!!! NO PLA !! PLA do not like water and sun beams.
Also remember - you should process a surface a skin of model after printing and spray on model any acrylic paint or structure paint for finishing.

Shortly - big models need some handwork after printing.

 

[chunder123]

HAs anybody tried replacing the metal planetary gears with nylon or compostie plastic gears to see if it is more quiet than the metal gears. they wont last as long but they might be alot more quiet. what are the specs of the cyclone gears gear teeth and pitch