This E.S. thread has been really helpful for my build, perhaps the following notes & photos will help other’s by giving ideas & some metrics.. I was surprised to hear Lyen sensorless works OK, very cool, which model of his controller specifically was that?
I just finished bench test of a 3rd GNG, and a trail ride on another gathering some data.
The 3rd bench test, with operation temps, sound and runout example is here, tad noisy bearing possibly the gear drive clutch, temps were similar http://www.youtube.com/watch?v=pTlIOTq7L5c:
Two short, 1 mile rides, varying terrain, where you can easily tell the wind noise and regular bike noise at speed is not much affected by the motor. Couple passing cars had no idea bike was powered, though likely they noticed the speed. Dogs don’t freak like a dirt bike. Ride 1, Ride 2, 2 minutes, sorry rough ride, cam on handlebar, won't do that again -
Ride 1, with dog intro : http://www.youtube.com/watch?v=7FHI4BUm8js
Ride 2, to Pacific ocean overlook: http://www.youtube.com/watch?v=WIU7mtzmW0c
Short, 1:30, bike walk around, LFP HK batteries and GNG install, & pannier rack & pack:
http://www.youtube.com/watch?v=bdWGte_1LWg
Battery performance, small inexpensive LFP HK Pack; and, also ‘morphed’ rear pannier rack and battery carrying bag (50 grm) separate thread:
http://www.endless-sphere.com/forums/viewtopic.php?f=14&t=38074&p=657106#p657106
Battery Bags & rear rack : http://www.endless-sphere.com/forums/viewtopic.php?f=14&t=38074&p=657111#p657111
Performance, 48v stock GNG w/ minimum 48v / 8400 mah LFP HK battery Pack –
The GNG, had No skipping, belt nor chain weirdness - just worked fine past several rides.
Just finished bench test of a 3rd GNG, and (couple short) trail ride on another, with, a bit of performance metrics. Overall build quality on GNG motor assembly is very similar, with very minor variation between two motors bench runs (temp, noise, runout, finish, etc). You gotta check all the torques, and add loctite.
Ran 5 miles on an 8400mah 48v LFP pack. Included a 750 vertical ascent with parts fairly steep paved road, no way I could manually pedal in ‘high’, but easy with assist 900 watt. Bike performed quite well, in view bike’s stuck in high gear. Certainly would be more efficient if down shift for climbs.
Bike is a four year old K2 Base, with a Alfine 8-spd internal hub, but the darn hub is stuck in 'high', so like a high geared tall 'fixie'. Not due to the GNG, hub jammed just before getting setup (go figure, works great for years, now hub is not so happy). Hopefully, fix the Alfine later this week. In spite of the 'tall' gearing, GNG still has impressive climbing. Couple places where the road grade is 13 degree (checked with a protractor sighting), a rather tough crank without power, w/GNG assist made the climb was easy. Lower gearing likely would climb under power alone?
Today’s ride ran through 192 watt, started at 52.7 volt, ended 51.47v. Peak amp 21.5 and 1014 watt. Low sag point dropped to 47.2 with short few second alarms on 3v cutoff. Cell variance .04v
Yesterday, short rides of cumulative 750 climb, parts at 13deg slope, shows 900-950 watt peak, about 19.1 amp peak. Pack started at 53.7v, with sag to 48.02 on steep pitches. Post ride, the cell variance was only .003-.04 volt.
Agreed, with earlier post, at wide open (WOT, flat ground), estimate 25mph, can barely keep feet on the pedals, cadence is pretty high. There's frankly nothing 'flat' around here, so 20-25mph is my guess WOT flatland.
Info on 'No - snap', precharge circuit, and automotive realay wire setup - see here – “rain psuedo-safe ?”
No zappy, no scary. A prior life, badly zapped with infinite DC 500 volt, near death experience, great fear of amps at this end.
Pre charge, and relay main bypass.
http://www.endless-sphere.com/forums/viewtopic.php?f=2&t=41770&p=657103#p657103
Great GNG thread, many thanks to all these posts, cool stuff.