hybrid enduro build

[vax]

Hello folks
Today I started my new project featuring:
1. GNG 1500W motors front and rear with belt drive, motors integrated into front and rear forks. http://www.gngebike.com/belt-chain-motor
2. 72V 40A infineon controllers
3. 5Ah 72V LiPo battery pack
4. Internal combustion range extender https://www.facebook.com/media/set/?set=a.585449294815245.148824.375979235762253&type=3
5. Triangulated steel tube frame with SaxTrack (Telever) type front suspension similar to this:

 

[vax]

The parts I have today
https://www.facebook.com/3dflux/photos/pcb.1321915057835328/1321913981168769/?type=3&theater
https://www.facebook.com/3dflux/photos/pcb.1321915057835328/1321913974502103/?type=3&theater

 

[vax]

Just bought couple of nice 20mm through axle hubs.
http://www.ebay.co.uk/itm/NOVATEC-Front-Disc-Hub-DH-DH41SB-20mm-20-32h-36h-Black-Sealed-Bearings-From-EU-/262279473466?var=&hash=item3d1113293a:m:md9MzVuTK-uUR1vKWRbDqGA

I'm gonna use 5M belt (20mm wide) and mount custom CNC-d pulley straight into disc brake mount holes.
Main braking will be with regen, and there will be small disc brakes atached to motor shafts

 

[vax]

Ok, more build progress
Bought used pit bike fork, which is gonna be a donor for my Telever front end design.

I removed all the inside stuff - springs, valves and oil tubes, I'm gonna use just sliders and tubes. There will be aluminium connecting plate between sliders, with car ball socket joint in middle. Also, gonna do cnc upper plate to tubes.

 

[vax]

Ok, here's some CAD-ing I've been doing with actual parts I have.
There's some of the stuff still missing, like brake system, belt and belt tensioner, but you get the idea of Telever fork.

 

[vax]

The wheels are laced! Hooray!
https://goo.gl/photos/rFV3exPMog8ujYeH7

 

[vax]

Purchased Speeduino ECU today for range extender. Seems an interesting project. I'm gonna probably modify the code, speeduino has stepper output for idle rpm. I want to use that stepper for auto-throttle - constant rpm holding. Entire engine will be precisely tuned for specific speed.
http://speeduino.com/wiki/index.php/Speeduino

 

[vax]

Redesigned the whole thing, moved front motor to the side, because routing chain through fork plate with ability to tension the chain was very difficult.

 

[vax]

I dropped the 2WD idea this time, because I found something interesting: 2-speed automatic gearbox (not CVT) from Babetta moped engine.
My friend has this lying at garage and he wants 30€ for it.
The operating principle is rather simple and ingenious.
Both gears are always engaged, but 1-st gear is pulling via one-way bearing. Second gear is 1:1 and engaged by centrifugal clutch.
The engine itsself is very compact and uses belt for main drive. So, very good candidate for electric conversion.

 

[vax]

OK, I haven't posted for a long time, again.
And once again there's a change of plan. I chose Alien Power C80100 sensored motor (50kv), which should be much better option than GNGbike 2.5kw (on 72V) motor.
Also, I 3D-scanned the generator so I can use it with Fusion 360 CAD.
For batteries I chose Turnigy 6Ah LiPo-s 20s overall.
So, todays progress:

The motor goes actually inside the crank case, which needs a bit milling the side open.
Diameter wise it fits almost perfectly - crankcase is 80mm dead. I'm gonna mill about 1-1.5mm off the inside wall, because I'm worried about eddy currents.
The whole gearbox will be stressed member of rear swingarm and shock absorber will be connected to upper mount point.
The gearbox case will also be 3D-scanned yet. I found really good place for that.

 

[Doctorbass]

If i can share my own experience with 2WD, here are my advices to make it work fine:
Tune the front motor controller to limit torque but not power. in other words, limit phase current and put the battery current to your desired power.

The weight transfer whren accelerating make the front wheel to mbecome very light so the traction is reduced. Phase current will be the key adjustment for solving that.

But power can be infinite 8)

Doc

 

[vax]

Maybe I use hub motor at front.

 

[vax]

Todays progress - machined the casing side open.
There was a bit fuckup, I wanted to get rid of the kickstarter extension on the case, but didn't check it through, it had opening where it didn't need to be. So, now there's hole which needs to be welded shut.

This is the position in which it goes into rear swingarm, sandwiched between side plates.

 

[vax]

A bit frame modelling:

 

[vax]

And with fuel tank mock-up