Danny Mayes
1 kW
For his land speed record bike i assume...
jonescg's NEW electric racebike BUILD thread!
- Thread starter jonescg
- Start date
jonescg
100 MW
Yep, definitely at least one of them going into the LSR bike, and possibly another track bike... 
Danny Mayes
1 kW
Frk that is exciting
jonescg
100 MW
Minor update on Voltron Evo's progress for the upcoming Round 3 of the eFXC. I have the relay control board managing the contactors inside the battery, doing things like opening the half contactor while the two quarter contactors are closed. Now that I have the Rinehart managing precharge and the main contactor, I could do away with the delay timer. But the BMS relies on a small reed relay which is powered by the NC loop of the BMS output, and this currently sits in the top of the battery pack. If I could consolidate this switching equipment, as well as the outputs for LEDs, it would be much neater. So I finally decided to learn how to make PCBs.
gEDA PCB is a pretty simple program, and it's free. Unfortunately you still have to go through the text file and make edits as standard practice, as the program doesn't allow you to chance certain things like hole diameters and clearing soldermask. Still, this wasn't a bad effort I think
It's slightly different to this screenshot, as there are suppression diodes on both relays as well as a new resistor for the 'BMS sad' LED. A buzzer will be fitted to this output too. The board also allows me to have an LED lit when the precharge relay is energised. Only a couple of minor problems, like the 3 A diode legs not fitting through the 1.1 mm diameter holes, but they can be surmounted.
I have just populated my first board, but can't really test it until I have a few more things made up, but it should make for a very neat package
gEDA PCB is a pretty simple program, and it's free. Unfortunately you still have to go through the text file and make edits as standard practice, as the program doesn't allow you to chance certain things like hole diameters and clearing soldermask. Still, this wasn't a bad effort I think
It's slightly different to this screenshot, as there are suppression diodes on both relays as well as a new resistor for the 'BMS sad' LED. A buzzer will be fitted to this output too. The board also allows me to have an LED lit when the precharge relay is energised. Only a couple of minor problems, like the 3 A diode legs not fitting through the 1.1 mm diameter holes, but they can be surmounted.
I have just populated my first board, but can't really test it until I have a few more things made up, but it should make for a very neat package
Rodney64
100 kW
Looks like you'll be able to design your own boards For batteries too Chris with this program.
jonescg
100 MW
Yeah I have tried to design some 2P boards for the 40C cells, but there seems to be a problem with the soldermask function. I could probably do it, but there is no way of removing the soldermask from the layout. It's good for removing soldermask from holes or vias, but not whole pads for some reason. Still learning...
DarylMc
100 mW
Nice work Chris.
Is there anything you can't do?
Don't answer that.
I had and idea for the Yasa motor.
Maybe you can save me some pondering.
Put the pancake motor into the frame.
Probably not on the left side drive facing inwards, since it would restrict ground clearance.
But on the right hand side of the frame, motor on the swing arm pivot with a shaft spinning about the swing arm pivot.
It would leave a lot of space for batteries or other stuff.
Is there anything you can't do?
Don't answer that.
I had and idea for the Yasa motor.
Maybe you can save me some pondering.
Put the pancake motor into the frame.
Probably not on the left side drive facing inwards, since it would restrict ground clearance.
But on the right hand side of the frame, motor on the swing arm pivot with a shaft spinning about the swing arm pivot.
It would leave a lot of space for batteries or other stuff.
jonescg
100 MW
The populated board:
Next step is to solder up the DB9 which carries all of the LED signals up to the dash. One for tomorrow - got a function at Scitech to work tonight
Next step is to solder up the DB9 which carries all of the LED signals up to the dash. One for tomorrow - got a function at Scitech to work tonight
jonescg
100 MW
I knocked up a test rig for the board and it all works well. I even made a new mezzanine for the board to sit on, so it's a complete drop-in kit for when I get over east. The main benefit to this new arrangement is an audible buzzer letting you know then the BMS is tripping, and an additional LED output for the precharge relay. It's powered by an OR diode pair, just to make sure that whenever the main contactor is closed, it is too. Unfortunately the LED lights whenever it's getting power from the controller - I probably should have put the LED after the diode pair.
I really want to work on a new dash for the bike. One with a few more road-legal features like a speedo gauge, odometer, ammeter and voltmeter, and a more compact set of indicator LEDs for the contactors and precharge. Making it all look neat and weatherproof won't be easy, but I need a challenge
I really want to work on a new dash for the bike. One with a few more road-legal features like a speedo gauge, odometer, ammeter and voltmeter, and a more compact set of indicator LEDs for the contactors and precharge. Making it all look neat and weatherproof won't be easy, but I need a challenge
jonescg
100 MW
riba2233 said:Hi, can I ask you something? I really like the transparent battery box, and I would like to build one for myself. What material did you use to build box, and how did you joined the sides of the box, with screws?
Thanks!
The battery pack enclosure is made entirely from polycarbonate. The front and back walls are 6 mm, the floor is 6 mm, the contactor shelf and upper shelf are both 4.5 mm thick, and the top/side covers are 3 mm. There are also internal dividers of 6 mm and 3 mm thickness in the sides and up the middle, respectively. The centre divider is held in place by a routed slot.
It's completely screwed together using M4 screws for the covers, floor and walls, while the upper shelves are help in place with M3 screws.
I spent about 2 years designing this pack, and I'm glad I took the time. It's got full isolation and insulation, it's water proof, easy to work on and it's clear - so you can see shit about to happen, before it happens
jonescg
100 MW
Well today was a cracker of a race! Three bikes (Varley, Ripperton and O'Hanlon) dukeing it out for first place! Danny Pottage onboard the O'Hanlon Voltron Evo came away with the win.
Oh, and we have a lighter battery pack 6 kWh, 55 kg - total bike weight is now 210 kg 8)
An EPIC marathon to get it built in time, but it's winning us races now.
I don't have a camera, but there are some tidbits up on www.facebook.com/efxc2014 if you're keen
Oh, and we have a lighter battery pack
6 kWh, 55 kg - total bike weight is now 210 kg 8) An EPIC marathon to get it built in time, but it's winning us races now.
I don't have a camera, but there are some tidbits up on www.facebook.com/efxc2014 if you're keen
voicecoils
1 MW
Great work Team Voltron!
Results and times for the Wakefield Park round attached.
Results and times for the Wakefield Park round attached.
SplinterOz
1 kW
Racing shot are uploading at the moment....
These guys were serious today
Race2-IMGP7699 by Splinter, on Flickr
https://www.flickr.com/photos/splinter/sets/72157647542026482/
These guys were serious today
Race2-IMGP7699 by Splinter, on Flickrhttps://www.flickr.com/photos/splinter/sets/72157647542026482/
jonescg
100 MW
Here's an easy copy-paste race report from the weekend.
I'm sitting here in Sydney Airport waiting for my fight back to Perth. It's been a long and rewarding week for team O'Hanlon Electric Motorsports.
We knew that Voltron needed to go on a diet, and the easy place to start was the battery. The 9 kWh LiPo pack was enough to do an 8 lap race of Phillip Island or Eastern Creek, but when you get 4 or 6 lap races at the shorter circuits all that weight is not helping your corner speed.
Mike needed a battery for his 2015 race bike, so it made sense that we smash out another battery for Voltron, but as a 168s,2p format. This gave us 6 kwh and only about 55 kg. We could also lift the battery up about 50 mm so Pottz has some more ground clearance. So not long after round one, Mike placed the order for another 400 LiPo cells. They were delivered to Sydney while I got busy building another polycarbonate enclosure and switch gear.
On Monday (the 8th) Mike and I arrived in Sydney to DeVice Motorcycles, where Voltron was being stored. We couldn't get to work as Matt the proprieter wasn't going to be in until Tuesday morning. Hmm, this was going to be a BIG job and time was tight. Come Tuesday we got in at about 10 am and started work. Mike went though each cell sorting them for low voltages and weeding out the one dead cell (they have upped their QC!). I spent my time assembling the pack and getting the bike out and ready for work. By the evening we were tinning copper. I had packed my soldering irons, copper. cell jig and third finger, so by 10 pm we had gone as far as we could. Wednesday morning at 8 am we were busy. Mike was building the booster chair for the new pack and I was building battery packs. It was a long process, but I managed to get three packs build, and a fourth one ready for Thursday morning. At 2 am we went back to Newtown for about 4 hours sleep, and were ready for more again on Thursday. We realised we didn't have enough copper to finish the final terminations to the contactors, so after some frantic calling around, we found a jewellery place in Marrickville who had just what we needed. I remembered an awesome e-bike shop was also in Marickville , so I called Voicecoils and got him to courier the copper over to us in Botany so we could finish the pack. Pottz arrived at about midday, so now we had three sets of hands to get it done. How many pro riders will stay up till dawn soldering 168 BMS wires with the team eh?
By 5 am Friday morning, all the BMS modules were soldered on and the pack was ready to drop in. We put the big pack back into the bike for transport and decided to swap the little pack when we got to the track, in about 3 hours time (!) We drove down to Goulburn and had about an hours sleep before heading out to the track and dropping the new pack in. It fit like a glove and plugged straight in 8)
Friday practice was good, but Pottz was dead tired. He put in a few 1:13s, with Ripperton and Varley (ridden by Jason Morris) bettering these times by tenths. David Hiley was on his modded Zero putting in some 1:20s, which was awesome given the power limitations. Once we Q'd it was shower time, nap time, dinner time, and then coma time :lol:
Saturday morning's race was one of the best of the series. Pottz on board Voltron Evo holds the title of "Best Electric Wheelie from the Start Line" and the commentators thought it was the bomb All three riders were putting in 1:11s and even a 1:10, with a hum-dinger of a 3-way battle for first. The lead changed so many times, with all three riders holding it for a time. Pottz would blitz them in the straights and sweepers, but Jason and Ripperton would catch him in the tight stuff. Voltron was handling SO MUCH better with 27 less kilograms of battery. The package now weighs in at about 210 kg. Unfortunately Jason's machine was having overheating issues, so he was dialling back. Pottz ran away with the win to an entire pit-wall full of spectators Ripperton second, Jason third and David fourth.
Race two was great too, but a bit of a procession. David handed the Zero keys to Craig White (a pretty good rider for an old bloke) who put in a pretty good 1:15, but the brakes were so overheated that he couldn't race at full pace. Pottz came away with the win again, followed by Ripperton and Craig. Varley crossed the line in fourth after more electrical gremlins.
Race three saw Jason struggle with yet more problems on the Varley machine, and Pottz had a shut-down at turn 10, right before the straight. After a 3 second restart he was in for the chase, again. Ripperton was passed a lap later, but he was clearly getting a bit frustrated with the whole second place thing. So much so he rode up behind Pottz in turn 10 and gave him a shunt... Rubbing's racing, but c'mon man, there was plenty of room to go around. Another one-two-three as per yesterday's, but Voltron was handing better than ever before. We're getting more drive out of turns as the rear suspension is starting to respond to our changes. When there's 27 fewer kilos from the bike, you can start to tune it properly.
Race four was the same again place-wise, but the late afternoon sun was still warm and the conditions were good. Pottz got off to a blistering start and raced through turn two faster than ever before - but forgot to change his brake marker for T3 accordingly and ran off track :lol: He joined the traffic at turn 4 and the Jaws music began... Within two laps he'd hunted Ripperton down and passed him up through turn 3, and lead the race for the remainder putting in consistent 1:10s. Craig White rolled the Zero in for third while the problematic Varley machine crossed the line for fourth. Pottz even scraped a knee for the first time around T10, which is pretty good given he's got such short legs and they are a long way up
Day2 -IMGP8014 by Splinter, on Flickr
So while the 1:09 record remains, I think 1:10s from Pottz on a track he's never ridden is pretty amazing. We thought Wakefield was going to be our toughest circuit, but in the end it was one of the best weekends for electric racing. Eastern Creek in a couple of months is going to be better, since Pottz has ridden it before.
Best of all we had so many people paying attention and asking questions about the bikes. The most common comment was "I wouldn't have believed it if I hadn't seen it, but wow they were fast".
Voltron Evo has been crated up in Sydney and will be shipped back to Perth for about 7 weeks before the last round. We hope to get some good track tuning in, and I can do a bit more work to it. I am SO looking forward to wheelie-ing the big girl over the hill at Wanneroo. It's gonna be wicked
I'm sitting here in Sydney Airport waiting for my fight back to Perth. It's been a long and rewarding week for team O'Hanlon Electric Motorsports.
We knew that Voltron needed to go on a diet, and the easy place to start was the battery. The 9 kWh LiPo pack was enough to do an 8 lap race of Phillip Island or Eastern Creek, but when you get 4 or 6 lap races at the shorter circuits all that weight is not helping your corner speed.
Mike needed a battery for his 2015 race bike, so it made sense that we smash out another battery for Voltron, but as a 168s,2p format. This gave us 6 kwh and only about 55 kg. We could also lift the battery up about 50 mm so Pottz has some more ground clearance. So not long after round one, Mike placed the order for another 400 LiPo cells. They were delivered to Sydney while I got busy building another polycarbonate enclosure and switch gear.
On Monday (the 8th) Mike and I arrived in Sydney to DeVice Motorcycles, where Voltron was being stored. We couldn't get to work as Matt the proprieter wasn't going to be in until Tuesday morning. Hmm, this was going to be a BIG job and time was tight. Come Tuesday we got in at about 10 am and started work. Mike went though each cell sorting them for low voltages and weeding out the one dead cell (they have upped their QC!). I spent my time assembling the pack and getting the bike out and ready for work. By the evening we were tinning copper. I had packed my soldering irons, copper. cell jig and third finger, so by 10 pm we had gone as far as we could. Wednesday morning at 8 am we were busy. Mike was building the booster chair for the new pack and I was building battery packs. It was a long process, but I managed to get three packs build, and a fourth one ready for Thursday morning. At 2 am we went back to Newtown for about 4 hours sleep, and were ready for more again on Thursday. We realised we didn't have enough copper to finish the final terminations to the contactors, so after some frantic calling around, we found a jewellery place in Marrickville who had just what we needed. I remembered an awesome e-bike shop was also in Marickville
, so I called Voicecoils and got him to courier the copper over to us in Botany so we could finish the pack. Pottz arrived at about midday, so now we had three sets of hands to get it done. How many pro riders will stay up till dawn soldering 168 BMS wires with the team eh?By 5 am Friday morning, all the BMS modules were soldered on and the pack was ready to drop in. We put the big pack back into the bike for transport and decided to swap the little pack when we got to the track, in about 3 hours time (!) We drove down to Goulburn and had about an hours sleep before heading out to the track and dropping the new pack in. It fit like a glove and plugged straight in 8)
Friday practice was good, but Pottz was dead tired. He put in a few 1:13s, with Ripperton and Varley (ridden by Jason Morris) bettering these times by tenths. David Hiley was on his modded Zero putting in some 1:20s, which was awesome given the power limitations. Once we Q'd it was shower time, nap time, dinner time, and then coma time :lol:
Saturday morning's race was one of the best of the series. Pottz on board Voltron Evo holds the title of "Best Electric Wheelie from the Start Line" and the commentators thought it was the bomb
All three riders were putting in 1:11s and even a 1:10, with a hum-dinger of a 3-way battle for first. The lead changed so many times, with all three riders holding it for a time. Pottz would blitz them in the straights and sweepers, but Jason and Ripperton would catch him in the tight stuff. Voltron was handling SO MUCH better with 27 less kilograms of battery. The package now weighs in at about 210 kg. Unfortunately Jason's machine was having overheating issues, so he was dialling back. Pottz ran away with the win to an entire pit-wall full of spectators Ripperton second, Jason third and David fourth.Race two was great too, but a bit of a procession. David handed the Zero keys to Craig White (a pretty good rider for an old bloke) who put in a pretty good 1:15, but the brakes were so overheated that he couldn't race at full pace. Pottz came away with the win again, followed by Ripperton and Craig. Varley crossed the line in fourth after more electrical gremlins.
Race three saw Jason struggle with yet more problems on the Varley machine, and Pottz had a shut-down at turn 10, right before the straight. After a 3 second restart he was in for the chase, again. Ripperton was passed a lap later, but he was clearly getting a bit frustrated with the whole second place thing. So much so he rode up behind Pottz in turn 10 and gave him a shunt... Rubbing's racing, but c'mon man, there was plenty of room to go around. Another one-two-three as per yesterday's, but Voltron was handing better than ever before. We're getting more drive out of turns as the rear suspension is starting to respond to our changes. When there's 27 fewer kilos from the bike, you can start to tune it properly.
Race four was the same again place-wise, but the late afternoon sun was still warm and the conditions were good. Pottz got off to a blistering start and raced through turn two faster than ever before - but forgot to change his brake marker for T3 accordingly and ran off track :lol: He joined the traffic at turn 4 and the Jaws music began... Within two laps he'd hunted Ripperton down and passed him up through turn 3, and lead the race for the remainder putting in consistent 1:10s. Craig White rolled the Zero in for third while the problematic Varley machine crossed the line for fourth. Pottz even scraped a knee for the first time around T10, which is pretty good given he's got such short legs and they are a long way up
Day2 -IMGP8014 by Splinter, on FlickrSo while the 1:09 record remains, I think 1:10s from Pottz on a track he's never ridden is pretty amazing. We thought Wakefield was going to be our toughest circuit, but in the end it was one of the best weekends for electric racing. Eastern Creek in a couple of months is going to be better, since Pottz has ridden it before.
Best of all we had so many people paying attention and asking questions about the bikes. The most common comment was "I wouldn't have believed it if I hadn't seen it, but wow they were fast".
Voltron Evo has been crated up in Sydney and will be shipped back to Perth for about 7 weeks before the last round. We hope to get some good track tuning in, and I can do a bit more work to it. I am SO looking forward to wheelie-ing the big girl over the hill at Wanneroo. It's gonna be wicked
jonescg
100 MW
Oh - and the shut-down fault was the lanyard connector being loose. Otherwise the PM150DZ has been performing flawlessly.
Come on Tony - share some of those awesome photos!!!
Come on Tony - share some of those awesome photos!!!
SplinterOz
1 kW
Photos have been post processed now... exporting them... upload shortly say about 60 minutes.
Note to all, my photos of the eFXC are all free to use as long as you attribute me as the photographer!
On the Flicker web page you can get to the download area from the image page and pick the size you want.
https://www.flickr.com/photos/splinter/sets/72157647542026482/
ALL UP NOW
Note to all, my photos of the eFXC are all free to use as long as you attribute me as the photographer!
On the Flicker web page you can get to the download area from the image page and pick the size you want.
https://www.flickr.com/photos/splinter/sets/72157647542026482/
ALL UP NOW
RIPPERTON
100 W
That was the best corner of the whole weekend. I was right beside Potts at the tip in point and kept him right round the outside to the exit. He really didn't know I was there as he was hanging off the right side of his bike and literally couldn't see me but when he stood his bike up I had to lean into him to avoid ending up over the pit wall and into the Team Honda pit.
We shoulder charged each other but luckily maintained our balance.
Actually I was just checking his bike for any loose wiring but it probly stuck his throttle as it took off like a scud
We shoulder charged each other but luckily maintained our balance.
Actually I was just checking his bike for any loose wiring but it probly stuck his throttle as it took off like a scud
Attachments
jonescg
100 MW
Yeah it was the same corner Danny was scraping knees on. It is a nice corner
Day2 -IMGP7788 by Splinter, on Flickr
Day2 -IMGP7788 by Splinter, on Flickr
jonescg
100 MW
Pottz just checked the GPS data - 226 km/h at the T1 braking point 
That's faster than the Superbikes! No wonder he's having trouble pulling up in time!
That's faster than the Superbikes! No wonder he's having trouble pulling up in time!
liveforphysics
100 TW
Thank you for doing such an awesome job making electric racing thrilling!
Grinhill
10 kW
Great summary of the weekend, Chris.
Congrats on the wins, and I hope you get to do some good setup work at the track over the next month.
Unfortunately the live web feed on Sunday was broken, so I had to make do with checking race results and watching numbers tick over on the live lap timing. :lol:
Congrats on the wins, and I hope you get to do some good setup work at the track over the next month.
Unfortunately the live web feed on Sunday was broken, so I had to make do with checking race results and watching numbers tick over on the live lap timing. :lol:
jonescg
100 MW
I guess now I can put some more battery build photos up. Mike took some great pictures of us while the 6 kWh pack was being built, and they are all up on Farcebook, but I can't see them since I'm not part of that machine.
But some pictures of the enclosure were taken while I was putting it together in Perth.
View attachment 1
Although this pack now has a big heap of vacant space up top, I didn't have the bike in front of me to design a more space efficient design. At least I knew that this pack format would drop right in, and it did It's about 50 mm shorter than the big pack, as we wanted to give Pottz more ground clearance at lean. The 9 kWh pack doesn't stick out too much, but the added weight meant the suspension was more compressed, so it was closer to the ground.
If I had the bike in front of me I would probably make it all fit in one 'tower' with the control box right on top and a longer Anderson connector lead, but hey, this one is working well for now.
But some pictures of the enclosure were taken while I was putting it together in Perth.
View attachment 1
Although this pack now has a big heap of vacant space up top, I didn't have the bike in front of me to design a more space efficient design. At least I knew that this pack format would drop right in, and it did
It's about 50 mm shorter than the big pack, as we wanted to give Pottz more ground clearance at lean. The 9 kWh pack doesn't stick out too much, but the added weight meant the suspension was more compressed, so it was closer to the ground.If I had the bike in front of me I would probably make it all fit in one 'tower' with the control box right on top and a longer Anderson connector lead, but hey, this one is working well for now.
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