Electric trike "recumbent" for "3" build

[Mihai_F]

Back with some updates, i mounted the front wheels back on the trike, the left brake caliper had an "interference problem" with the frame and i had to shift it a bit (cut off and reweld) to clear the frame. Had to elongate the motor phase and sensor cables, also finished the controller "enclosure installation" and internal signal wiring, all power cables will be installed when i'l mount it on the trike, but before that, i need it inside house to connect it to a test controller in order do develop the SW for it, mainly the serial comms between them. So all the parameters for drive, like throttle input, F/N/P/R command, and system parameters are transferred between main controller to secondary controllers serially (UART RS232 for now), except the brake signal which is "hard wired" for safety reasons in case serial comms "go berserk" if the brakes are pulled every thing stops.
here are some photos:

 

[Mihai_F]

Back with progress, i mounted the front drive controller and all the power and signal cabling needed to it. Made the SW for all 3 controllers to share data and all the functionalities.
Now comes the part where setting/tuning the front drive becomes difficult, mainly because the rear drive has changing gears, and the wheels speed difference between front and back is quite big, especially on the climbing gear (1st).
In order to synchronize them somehow, i'm thinking to limit the front drive wheel speed, basically it's a play/fiddling between phase current and voltage and max power draw allowed.
The "problem" i'm trying to mitigate is the front motors have a Kv of 22, and at 60v they want to "spin" at 100km/h (20" wheel) at full "blast", and from calculation there is NO way to rewind them at half of that Kv and maintain the same power capacity and loses, because lower Kv means more turns, and due to space limitation in the slots it means less strands in parallel and that means higher winding IR and loses.
This back and front wheel speed mismatch i foreseen coming, but my confidence is that FOC will be capable to mitigate to some degree this "issue", by limiting Vq and tricking the motor to receive only 1/3 of that 60V from 16S battery.
Probably the correct solution for this rig is to make a 10S battery, since all 3 motors are basically for 36V, although the rear drive works really good on 60V since i can pull way more power out of it, than factory speck. Will see how the front drive tune-up goes
Here are some photos of the installation.