enduro E-Bike ,need HELP !

[renago]

Hi to all !

I am about to launch my project that is to make an enduro E-bike .
with a central powerful motor , say 6-10Kw .
central gearbox .
26 front , 24 rear or a 19 moped rim,
main use is off road , where today I go with my 450 enduro motocycle -
the frame will me custom made , I think in aluminum 6065 , but I am not fully fixed on that yet.

I would like to start from the motor
I have collected a lot of info on many different motors , but I am still rather confused , which one would you suggest ?
http://www.cpmotors.eu/en/elektromotoren/cpm90-twin-4-to-10-kw/ , but I know that they will issue some new stuff soon !

http://www.heinzmann.com/en/electric-and-hybrid-drives/disc-motors/synchronous-motors , thinking at PMS 120 , , has the big vantage to run at high voltage /low A , think is the same that KTM are using .

http://www.thunderstruck-ev.com/perm-pmg-132.html , alternative

http://www.electricmotorsport.com/store/ems_ev_parts_kits_EMC-ME0909.php , a good possibility , but rather heavy

http://www.electricmotorsport.com/store/ems_ev_parts_motors_pmac-ss.php, not bad .

http://www.rctigermotor.com/show.php?contentid=146

http://www.hobbyking.com/hobbyking/store/%5F%5F5142%5F%5FTurnigy%5F80%5F100%5FB%5F130Kv%5FBrushless%5FOutrunner%5Feq%5F70%5F55%5F.html

thanks for any help,and suggestions.

Renago

 

[bzhwindtalker]

You could also build a mid drive setup with a hub motor mounted inside the frame, that would ease the gearing and hubs are cheap and available big brushless outruners !

 

[bzhwindtalker]

some more info on those systems : http://endless-sphere.com/forums/viewtopic.php?f=6&t=38553

I use this bike for enduro riding on tight trails, I only push it to 2500w but I could go much higher, I still goes from zero to 40kph in a heartbeat, with a 65kph top speed.

 

[renago]

thanks for the suggestions.
after reading many posts in the last months , I came to a conclusion :
that many guys have done a nice work , but failed or were un happy due to the motor / controller weakness.
especially the hub motors , they are all made for pedal assist bikes, so they work fine in this range .
my objective is to have an intense off road use , so I will need a professional motor.
an old saying sounds more or less as : I am not so rich to buy cheap !

at present I am oriented towards a Perm 120 motor .
has any one had direct experience with this kind of motor ?

also on gearbox I have some problems , neither Pinion or Suntour want to sell to me directly .
They sell only to Bike manufactures , I can understand their company policy .
so I am forced to build my own gear box .
which is a real nightmare .
I will have a spin off from a small motorbike , for gears and the desmodronic shaft .
weight will be rather heavy , but we will see .

rgs Renago

 

[incememed]

Renago, be sure to keep us updated on your build.

I've been building a bike for two years now, with similar objectives. Some observations made along the way are
I'm running a Turnigy 100/80 130kv at a peak power of 3kW. This will keep most people happy on the mtb trail, but on the low side in the enduro trail. The motor is said to be able to handle some 6kW, so I'm planning to stick with this motor for some time ahead. Perm seems great, but what about the weight?
Get a sensored controller and install sensors. I'm a student of electrical engineering, and take pleasure in making my own controller, but its a very tedious process.
Gearbox - there just doesn't seem to be any that fits and that can survive in mud. I made a simple reduction box using straight cut spur gear. An oil bath version is on the drawing board, will be something like this



I'm usually on the mtb trail, but the other day I re-geared to get a top speed of 50+ km/h and went to the enduro trail to ride with the motorbikes. In hindsight I lost too much torque from the re-gearing, but overall it was quite feasible to ride in this environment, didn't get in the way too much

[youtube]nFBD_Bjj5BU[/youtube]

Good luck with your build, I think enduro is the right way to go electric. The bike can be lightweight and speeds are low.

/Mattias

 

[renago]

Hi Incememed

nice video you have posted .
that's more or less the idea .
In my area we have more hills and mountain tracks .
so the goal will be even more difficult.
after going through almost all treads on this and other forums ,over 2 mounths of reading
I have made up my mind on the motor.
it will be ............a Crystalyte HT 3525
as simple as that !!!
this choice has been taken for a number of reasons :
my low experience in the field ,
low cost of this motor , so if the final product will not be up to expectation , I will have limited the wast of money .
the relative high torque and power this motor can give ,
and the possibility to have a water cooling system , have a look at Keynes DH project ,http://endless-sphere.com/forums/viewtopic.php?f=6&t=26029&start=240 very smart indeed .
also http://endless-sphere.com/forums/viewtopic.php?f=6&t=37489 , has made a valid and compact enduro e-bike .
my plan is to make 2 prototypes .
first one very classic , using the HT3525 as a hub motor , for my girl friend .
second one much more radical using HT 3525 as a central motor.

concerning gears , the only good solution would be Pinion , but they do not sell to DIY builders .
I have already asked they directly and trough a dealer .
and as far as I heard they do have some delay on mass production .
Suntour gearbox is out of production ,
not much left
but with a Cry HT3525 , I hope to get the transmission reduction right so maybe I can avoid a gearbox !

I will keep this thread updated .


Renago