Go Kart conversion - Mars

[jamo96]

Hi guys

I have been working on my conversion of a little go kart of mine. Formerly it had a 100cc 2-stroke engine, direct drive (you had to push start it. It went well but I always wanted to convert it to electric.

Initially I just want to match the performance of the original motor. Top speed was ~85km/h, there was also a minimum otherwise you would stall... Acceleration was great from about 30 - 70 km/h.

I bought a Motenergy ME0201013001 from EV works - $450 - http://www.evworks.com.au/index.php?product=MOT-MARS-ME0201013001

I designed and had made a motor mount.

I purchased a 24 Mosfet Controller XJC8b116 kit. Built the controller with 4110 fets. Current limit is at 200A batt, 400A phase at the moment.

I have been slowly putting it all together over the last 6 months. It is currently at my parents farm so I only get to work on it when I make the 2 hour trek. I have put larger, treaded wheels on it at the moment for gravel driving. I also mounted a new larger seat, the previous one was kids size I couldnt fit in properly. Go kart has a Haase chassis.

Top speed so far is 77km/h. I haven't done any power measuring as I only have a turnigy watt meter at the moment. Buying a CA soon.

Things to do: Chain guard, Controller cooling (fans), move current accelerator and use existing cable and spring pedals, replace brake master cylinder (keeps needing to be bled), mount batteries in sidepods and re attach them, mount controller behind seat..

My other ride:
http://endless-sphere.com/forums/viewtopic.php?f=6&t=33659

Pics:

Video test spin up (after I had modified the throttle, I soldered a trim pot in the -ve line to adjust the bottom end) This is nowhere near full throttle.

[youtube]http://youtu.be/pKW4cxSgD3g[/youtube]

Very happy with it so far.

 

[neptronix]

Cool, a motenergy/mars motor with an infineon controller..

I got the 4201 for my ebike.. engineer told me it would be loud on a pulsed DC controller.. sounds like it is.. i can't wait to see some ride vids - subscribed to your youtube channel now :]

What voltage are you running?

p.s. might wanna put a bolt in the threaded part of the driveshaft to prevent your keyway from slipping out, hehe.

 

[adrian_sm]

[youtube]pKW4cxSgD3g[/youtube]

[youtube]pKW4cxSgD3g[/youtube]

 

[jamo96]

What voltage are you running?
p.s. might wanna put a bolt in the threaded part of the driveshaft to prevent your keyway from slipping out, hehe.

Running 14s lipo. I'm just using my ebike batteries for the moment. Havent worked the max rpm at that voltage yet. Tyres are 16 inch, front sprocket is 26(or 24?) I can't remember of hand. Rear is 74. And max speed is 77km/h. I'll do the math later.

Yes key is just held in by the grub screw at the moment. The sprocket should be facing the other way but I can't get at the set screws... need a longer hex key!

Thanks Adrian I need to copy the right url.
Driving videos will follow. Too wet today for driving.

 

[jamo96]

I got the 4201 for my ebike.. engineer told me it would be loud on a pulsed DC controller.. sounds like it is

Yeah motor is a little loud driven with block waves, there is a certain band of rpm where it is really loud (not quite 2 stroke loud though)

 

[drewjet]

The sound is very similar to what my Suzuki makes with a Kelly Controller. Good to know the infinion will drive it just fine.

I have been running 20S for the last few years and the motor is fine with that, probably be OK up to 24S,

 

[winchmeup]

The original post has been a while but i thought i would join in.

I'm in Adelaide. (had a quick scroll through and didnt see anyone else)

I have two kids gokarts. I like to call them Car Boot Racers as they fit in a car's boot. They start out as 50cc pocket bikes and with a little cutting and welding and a school chair seat they're good to go. We usually just go to a car park or school, throw some cones out, instant racetrack. No one gives us grief as i think they look at it as a toy.
The original is a 900w brushed scooter motor on 24v 16AH Golden Motor Battery Pack. (this has been dying a slow death and now is pretty useless) It usedto do about 25km/h even with me in it. It would snap the kids head back with the 7 year old. Probably going to put 36v lipo through it to just liven it up again.

The other is still on going turnigy 80-85 170kv 15s lipo and Keywin controller. My other posts have shown i have had a lot of probs with the controller but ..... I think its all good to try tomorrow. Cant wait just to see how it goes.

this site is amazing and might a say a little intimidating just how smart everyone is. Thats why i havent commented on posts since joining.

Regards Steve

 

[winchmeup]

sorry the first message was ment to be on Aussie list.

This is still a cool build. i assume you are going to paddock bash in this?

any idea of speed and performance?
Steve

 

[jamo96]

A package arrived in the mail today...

A size 4 Sevcon Gen4. 48V 450A controller. I got it at a discount from a university who bought it for their ev and then decided to use 2 smaller controllers for dual motors and a virtual diff.

Should give the motenergy motor a nice kick in the pants.

Now I have to shell out for the controller software :l (and decipher the manual for that matter)

 

[jamo96]

While I've been waiting for my Sevcon software and CAN interface to arrive I did a few mods to my 24 FET controller.
-replace silicon pads with kapton film
-contracted some terminals, space for a fuse as well.
-contacter and shunt installed
-4 fans

Still have a few things to tidy up wiring wise. But all works well, fans move plenty of air
Controller is being used on a motenergy pmac me907.

[youtube]kvDHB19b3tI[/youtube]

Fans are a bit noisy but work well.

 

[jamo96]

Also received a 54 and 62 tooth sprockets to replace the 74 tooth one currently.

 

[nechaus]

While I've been waiting for my Sevcon software and CAN interface to arrive I did a few mods to my 24 FET controller.
-replace silicon pads with kapton film
-contracted some terminals, space for a fuse as well.
-contacter and shunt installed
-4 fans

Still have a few things to tidy up wiring wise. But all works well, fans move plenty of air
Controller is being used on a motenergy pmac me907.

[youtube]kvDHB19b3tI[/youtube]

Fans are a bit noisy but work well.

job well done!!!

 

[winchmeup]

Very impressive work.
Just read you other bikes. Do you have any link or blog etc on those