Jawnn,
I am kinda laughing, I guess I am confusing you. As I get more information from you I try to narrow the power transmission design down to something that will work, we are well past the 2.6 inch motor pulley. We have determined that it will not work. I don't know where you came up with an 11 inch pulley, Tractor supply has v belt sheaves in the "B" size with diameters of 12, 10, 9, 8, and smaller, very cheap. That is why I would like to incorporate this drive.
My 8" 3vx sheave cost $80, the bushing was about $15 I think, My whole 1st stage in the 3vx cost about $120.
The "B" drive 12 inch sheave is about 17 dollars, bushing about 10 dollars.
The parameters that I know, and that I am working with are as follows:
Motor, Mars 909
Motor rpm, 2130 at 24 volts
Wheel size, 20 inch diameter
Weight, 600 pounds
Maximum slope, 16%
Top speed, 20 mph
Cruising speed, 15 mph
Maximum rear sprocket size, 5.5 inch in diameter, This Will Fit? This really helps us
I spend about an hour figuring out these drives, not really doing anything, kinda of relaxing hobby the last couple weeks.
Now before I continue,
Answer this, do you feel that this trike can be converted?
Will it handle the weight?
Can the steering be fixed? Is the steering trail and rake incorrect. Or, is the front of the trike too light?
Can the trikes brakes stop this load safely? If not can they be improved?
Is there a problem with the rear wheels? Spoke breakage, tire slippage, poor rims?
Do you feel the frame of this trike is strong enough?
Explain the axle and how this works. Is it a live axle with one wheel drive? What is the diameter of this axle?
The motor and drive train will probably add about 30 to 35 lbs to the trike itself. I would put the batteries in the trailer. Get rid of the cargo behind the seat. Put that stuff in the trailer.
If the above problems are easily and cheaply solved then lets proceed.
Jawnn, I don't know a thing about these kinds of trikes. I commute in the northern suburbs of Dallas, TX. If I rode your trike here on a daily basis for my commute I would calculate my life expectancy to be less than a week. This is not a joke. This town is not designed for bicycle traffic, most certainly not safe for a trike. To protect my life, I take shorcuts on my ebike that your trike could not navigate.
I have ran a small business here for years, mostly metal manufacturing and installation of metal products for light commercial construction. I have the metal fabrication tools, skills and facilities to build just about anything out of steel. My Dad is a retired engineer, He designed machine tools, heavy industrial equipment, etc. I worked with him a lot, installing drives of all kinds, for applications from the extremely small to the gigantic, I know this power transmission stuff inside and out. Soooo,,,
If that trike frame is strong enough, I would fix that steering wheel flop you talk about on your blog. The front wheel of your trike, from your description, cannot supply much stopping force because it is too light. Well adjusted brakes of any type should be fine, don't waste the time on hydraulic disks, without weight on that front wheel the stopping force cannot be improved with expensive brakes.
I would like to keep the pedaling input. Two hubmotors on the rear would eliminate this, and require some expensive welding fabrication.
Now again, if that trikes frame is strong enough,,,,,,
Motorcycle wheels.
this is what I would do.
Go to a motorcyle salvage yard.
Find two small matching rear motorcyle wheels with hub brakes, not disk brakes. Something off of a small dirt bike. Bald dirt bike tires that are not dry rotted.
Get the brake cables and foot pedals too. Get a couple of motorcycle front brake levers, have them throw in the front brake cables if you can.
Get as much of the rear brake system as possible.
Saw the back of the trike off.
Make a live axle.
The rear wheel of the motorcycle has an axle bolt, have a welding shop cut the heads of the bolts off and weld these bolts to each end of an axle tube. Now you have a stub axle. You will need a couple of bearings for a live axle, think go kart live axle. Many types availble that will fit that axle tube.
Mount the motor so that it drives one wheel directly, using a 2 stage reduction, 1st stage a belt, second stage #40 chain.
Have the welding shop mount your current freewheel on the live axle. Near the opposite motorcyle wheel, have the welding shop weld a plate to match up to the sprocket holes on the second wheel.
See, let me describe how this works.
Both wheels get mounted to the stubs. Just inside of the wheels on the axle tube go the live axle bearings. These bearing have bolt holes so the whole axle assembly gets bolted to the refrabicated rear of the trike.
One wheel is attached to the live axle by the plate that is welded to the live axle. The plate on the live axle is bolted to the old sprocket holes on one wheel. Your freewheel is mounted directly to this axle tube. Your freewheel for pedal power is mounted on this tube.
The other wheel is freewheeling on its axle stub. Only the motor can drive that wheel. A freewheeling adapter could be mounted to the jackshaft sprocket , making pedaling easier.
Now you can pedal, keeps you somwhat legal.
You can stop. The motorcyle hub brakes will stop you just fine.
That axle will handle the load just fine.
This is what I would do. To your trike.
Any metal fabricator will know exactly what I am talking about. You supply the parts. The axle bolts, motor, and jackshaft assembly. Make sure they have all the parts necessary, including the belts and chains, sprockets. They will refererence this for holes, spacing etc. I would say it could be fabbed up for about $500 labor, $100 for steel. Shop around, some shops do not want your business, or do not have time. They will overbid. And they have good reason for this. They may not have the right person for the job, etc. Small welding shops generally starve in the winter, too busy in the summer, just the way it is.
You do the actual installation of wiring, motor, jackshaft, wheels, brake cables etc.
So, before I do more calculations, kinda sit down with a pencil, determine exactly what your needs are, what your budget is.
Oh yeah, #40 chain is much stronger than bicyle chain. I strongly advise you not to even think about bicycle chain of any kind on the motor drive. It will fail promptly. On a motor this size, it could kill you. No shit.
I have a 1.6 Hp Scott Permanent Magnet Motor. I travel 30 mph. Bike and me weigh 370 lbs. I use #41 chain that is many times stronger than bicyle chain, I am past its rating. When the bike weighed a hundred pounds and had a 1 hp motor the chain went about 8000 miles with a couple of adjustments. Now that I am beyond the #41 chains rating, not much though, the chain needs adjustment quite often. When it needs replacing I will go to #40 chain that has about 3 times the power rating. If I used bicycle chain of any kindI doubt it would last a week on my ride.
Bicycle chain is made for very low power inputs, does not last many miles on a bike, is not designed in any way to run at the power levels we are talking about.
chuck