Kelly Hub Motors

jake,
I have been testing the 6kw motor for use on the front wheel of a litestar / pulse inclosed motorcycle. The first problem was very little torque at low speed, infact it had a hard time in reverse and could not traverse the incline from my driveway to the garage. On the plus side it ran like a bat at of hell above 30 miles an hour, it only took about 12 seconds to get there.
The second issue was using the hub motor in the front wheel, I am not convinced it is capable of being used as a steering wheel ( side loading). The motor came with a defective bearing, I took the motor to a local rewind shop to see if they could rewind it for more torque, they found the bearing problem.
The Kit came with plugs and controllers, it was pretty slick right out of the box, the programming was easy to do and you could reprogram on the fly ith a laptop.

I just got off the phone with Steven from Kelly controller, they are sending me another 6kw motor that is suppose to be wound for more torque, the language barrier is a problem when you try to interface with the company. My advice on that front is to pay with a credit card,

I am still in the middle of the electrical protion of my hybrid project. I am hopeful the problems will get resolved, give me about 15 days and I will update you.
 
Hey calno magnum,
Thanks for your reply!! I have been looking at this motor for quite a while now and researching on others. I have found that this motor is great for the price and ability to get to 100kmh plus, compared to others. Thanks for giving me a detailed explanation of the down sides and upsides. I have also found the customer service good, but also hard with the language difference. Im going to be using the motor and 72v 8kw controller to create a motorcycle for commuting and solely driven by the hub motor. The frame im going to be creating myself and im going to use various parts of motorcycles and pit bikes. Do you have any pictures of the hub motor and kit, controller etc. Your project sounds great! Are you using the normal petrol driven motor and the kelly hub motor as hybrid? Are they sending you that second motor for free? or you purchasing it ?
I'm so gracefull for your reply
Thank You
and please keep me up to date. Please, contact me by mail if you will; Jake@saund3rs.com
:D
 
Hey guys, I am looking into this motor / controller combo as well. I am looking to use it in a reverse trike to drive the rear wheel.

My concerns would be getting an acceptable accelleration out of it with a 700lb vehicle (with me in it) and the rear bearings holding up under side loads.

Also, I am wondering out loud how it would do with good cooling pushed up to 96v?

Calno, is the side opposite the brake rotor also tapped, possibly to put a drive sprocket should I go Hybrid (A distinct possibility)

fyi, here is my build blog outlining some of my other crazy projects :)
tshtrikes.com

Tom
 
Do you have any pictures of the hub motor and kit, controller etc?
I didn't take pictures when I unboxed the kit, but it looks the same as the picture of the keb72801 on the website


Are you using the normal petrol driven motor and the kelly hub motor as hybrid?
I am using the drivetrain from a Suzuki 659 bergman scooter after the electrical phase is complete, that will allow me to prove the electrical portion, and move the project around to the paint shop, upholstery show, graphics shop, machine shop.

Are they sending you that second motor for free? or you purchasing it ?
I am paying shipping, however my aggreement with Kelly Controller is to test the motor, if it doesn't work I am going to have to scrap the electrical portion of the project, which will mean no reverse, no air conditioning, no hybrid, and send the kit back to kelly. Or I will have to make a choice to go to all electric, using 2 hub motors. But after the testing I'll know what setup will work for that weight/

todayican2 asked;
My concerns would be getting an acceptable accelleration out of it with a 700lb vehicle (with me in it) and the rear bearings holding up under side loads.
I am not sure what acceptalbe acceleration is for you, the high speed 6000kw motor on the litestar with me in it was 6 sec to 40 mph, that will change when we test the high torque motor. The motor has shipped this am so give me a chance to install and evaluate. I don't think side loading is going to be an issue in the rear for you, my install uses it as the steering wheel.

Also, I am wondering out loud how it would do with good cooling pushed up to 96v?
I didn't really notice the sound, it was really quiet. I was going to use a sound effect at low speeds, something like the jetsons car.


Calno, is the side opposite the brake rotor also tapped, possibly to put a drive sprocket should I go Hybrid (A distinct possibility)
its not tapped, but the cover for the hub is, the hub cover drives the 2wheel, I think you could put a sproket there, a nice belt drive would be sweet on your application,, on a side note I think I have a fiberglass body for your trike, if you could seat 2 people side by side
 
Lots of good stuff going on here :)

Calno, when I said I was wondering out loud, i meant I was wondering how you and Jake (and anyone else reading) :) think the Kelly motor would do at 96v and say 300 amps max.

Very interested in hearing about the body idea too, although I am planning a 1 seat, maybe with a "jump seat" in the rear.

I do have plans for a front wheel drive trike using a geo metro drive train in the near future though...
 
This is spam if I ever saw some. Why not just go to the "For sale" section or the REview section and tell everyone what you are selling these days.
 
Morph, I dont get it. Talking about something besides what your using is spam?

I cant speak for the other guys on this thread, but this will be my 2nd ev and 5th vehicle that I have built from scratch. Ive been looking at Marks motor closely, but feel that since it rides on spokes (and is a bit more money, probably worth it btw), The Kelly is worth looking into, If you dont agree PLEASE tell me so (I dont want to lay down 1400 for a motor / controller that has problems)

It does concern me while I am at it that so few people are talking about this motor anywhere out there on the web...
 
I was wondering if that when you do some tests with the high torque motor, if you could post them here and maybe show it in a video? That sounds like a great deal with kelly controllers. They are soo helpful and really usefull with things like this. 6 secs to 40mph is pretty good for me and i dont think that will be an issue with my project. Once i start my project i will create a thread, although my project is still in the desgining, planning stages, It will be a big test for the hub motor as i will be using it for 30-40k trips every day, a commuting pitbike/motorcycle.

-------

i dont understand either what you are talking about morph, we are discussing the kelly 6kw hub motor, a motorcycle class hub motor. It is quite pricey so we created a thread to see what others have done with it and to generate ideas for our projects with it. We are looking for other options. This is my 7th EV and i have been looking into different electric motors/brushless hub motors for years now. This is one that i found and as i said before, wondering what other ppl have done???
 
Yeah of course. I have Used the 1000w motor and 100 amp for 2 or 3 projects all ending because something breaks.
Well right now i only have one that i use, this is one of them chinese electric scooters which i bumped up to 36v with a 100 amp controller and added a 1000w motor which in turn gives me 50-60 kmh. I created one similer for my brother with a 750w motor and same controller. I welded and fabricated motor mounts for both.
Thread on MES 1st one; http://www.modifiedelectricscooters.com/forum/topic.asp?TOPIC_ID=665

Before these scooters i had converted my petrol pocketbike to electric using the controller and motor i have on the scooter, it gave me 70kmh with the right gearing, i later found that the torque was too great for the wheel, so it ripped the sprocket off. This is the thread from it in another forum; http://www.modifiedelectricscooters.com/forum/topic.asp?TOPIC_ID=541 .
EValbum; http://www.evalbum.com/2610

Then before this one i had converted my mini petrol dirt bike to electric, same setup again this only gave me around 40 kmh because i was using a toggle switch instead of a controller because i could not afford one. Just an on/off switch, although i got some great torque with my 5-1 gearing.
EValbum; http://www.evalbum.com/1620

One of the other three was an electric bike that i built, it used a traction drive from a wheel mounted ontop of the rear wheel, welded in place with a strap to tension it against the wheel, i also used a toggle switch. 24v with a 180w motor gave me 20 kmh and a great range because the motor doesnt take as much strain as if it were the main drive wheel. No pictures or video for this one.
The other two or three scooters/school project scooter evolved from a push scooter. The school project scooter was a mail scooter designed for long distance riding.
Most of the videos to all of these main evs i built can be found on my youtube channel; The00Snake.
This is litteraly my cv of electric vehicles, i started when i was 13 and now going up to motorcycles at 15.
Can you explain yours?
 
morph999 said:
This is spam if I ever saw some. Why not just go to the "For sale" section or the REview section and tell everyone what you are selling these days.
Click to expand...
Do you even know what "spam " is?

http://en.wikipedia.org/wiki/Spam_(electronic)
 
todayican2 said:
Lots of good stuff going on here :)

Calno, when I said I was wondering out loud, i meant I was wondering how you and Jake (and anyone else reading) :) think the Kelly motor would do at 96v and say 300 amps max.

Very interested in hearing about the body idea too, although I am planning a 1 seat, maybe with a "jump seat" in the rear.

I do have plans for a front wheel drive trike using a geo metro drive train in the near future though...
Click to expand...

whe you ask what they would do, what are you looking for? acceleration, top speed, efficiency? If you can give me the weight, drag co-efficiant, road grade, acceleration, we could make a pretty good estimate on performace. \

I'm a real fan of airplane kits, I was looking at a Cozy IV body and thought to myself how cool that would look without the wings. ( I better watch myself, that morph fellow might think this is more spam) the reverse trike lends itself well to the outline, plus is the bulk of the body was fiberglass of carbon fiber, lighter is faster.
 
only1jake said:
hey calno mangum,
what else did you buy with the hub motor? compact assembly, throttle??
this one; http://www.newkellycontroller.com/product_info.php?cPath=36&products_id=134
if this one is good quality theres no need for me to be looking into magura throttles...
thanks
Click to expand...
I got that one with the kit and ordered a pedal as well, I ended up using the twist throttle, its pretty smooth and it has an on/off switch built in. 35 degree range I think.

oops someone might think this is spam
 
todayican2 said:
Morph, I dont get it. Talking about something besides what your using is spam?

I cant speak for the other guys on this thread, but this will be my 2nd ev and 5th vehicle that I have built from scratch. Ive been looking at Marks motor closely, but feel that since it rides on spokes (and is a bit more money, probably worth it btw), The Kelly is worth looking into, If you dont agree PLEASE tell me so (I dont want to lay down 1400 for a motor / controller that has problems)

It does concern me while I am at it that so few people are talking about this motor anywhere out there on the web...
Click to expand...

Don't give the troll the satisfaction,
 
The trike I am going to build will be fairly similar to the 250cc one I just completed the frame and running gear on, it can be seen at tshtrikes.com

here are some guestimates:

500lb empty
.20 or a bit less cd
reverse trike (of course)
composite sandwich body (just like a cozy or Long Eze)
2 seats (more of a one seater with a luggage area / "jump seat" in the rear
front spindles, brakes etc from a late model raptor quad
mini cooper 10" tires
"space frame" for the chassis essentially a box made of 1" sq 16ga steel 90" long, 22" wide, and 8" high. It will carry 72 to 96v of headways (about 60ah) "inside" the forward frame ahead of and under the forward riders feet.
Aviation "bubble" canopy.

Kind of a cross between this:
http://www.treehugger.com/hyperrocket-ford-3-wheel-motorcycle-001.jpg

and this:
http://www.blogcdn.com/green.autoblog.com/media/2009/09/myers-orange-black-front_630.jpg

With mine being "full fendered like the second one, but canopy roof line like the first one.

Motor choices are all over the place currently :)

a D&D sepex at 84 volts with the sevcon controller driving a chain?
Marks Motor at 96v?
The Kelly 6k (8k?) motor at 72 or 96v?
Etek / Mars?
Agni?

In any of the scenarios I plan to mount a subaru robin 4.5hp motor in the rear and either run a chain off a centrifigual clutch to either the rear wheel (If I use a hub motor) or to a second sprocket on the electric motors output shaft as a "highway running range extender" (possibly driving an alternator as well to charge the 12v gear)

I am hoping for acceleration to match a prius, and 75mph cruise.
 
IMHO Morph had an opinion and made a bad choice with an accusation. (and used some unfortunate tin foil reference.)

But....

In looking at his rating and post count, Here is what I think, just my opinion, I think we recognize that were here to compare notes, gain knowledge and in the end save ourselves from costly and dangerous mistakes.

Even Aussie Jester is allowed to have a bad day.

My desire is to say Morph, it doesn't look like there are any spammers present (who knows, that could change though) and to thank you for all the posts you've made and welcome any ev related help you (or anyone else can offer)

There will be no "probe" comments coming from me :)
 
good to read about all the projects guys as I sit trying to recover from a stroke earlier this year.Electric propulsion is something I've been waiting for all my life and now at last it looks like it's arriving. these brushless DC motors look like the future to me;I can't wait to get into them.A Kelly Hub motor in each front wheel of a back to front trike seems like a nice challenge to me.tubular space frames have been a lifelong fascination and would be a good starting point. I imagine that arranging reverse plus speed and power controllers for the two contra-rotating motors will take a bit of advice from you electro-boffins, when the time comes, unless anyone wants to explain it at this stage in case other people have similar plans.Good luck All, and thanks,
Another Kiwi (Stuck in UK)
 
Gents:

I'm also interested in these new larger hub motors. My vehicle is almost on all fours (all threes?) with todayican's next build- 400lb empty weight, kevlar/carbon composite envelope monocoque, Quadracer front end and KX250 Unitrack swing arm. I have a way-cool Honda Odyssey 350 handlebar, which has all the controls built in, but I'm currently working on fitting Wilwood disc brakes and fabbing the master cylinder configuration.

The rear wheel hub motor is the dicey bit with all these designs. I'm less worried about the bearings than the integrity of the rear wheel. Side loads are, of course, controllable by the pilot, so I'm probably going to use Mark's spoked hub wheel and be careful with it until I can figure something else out. Nothing else keeps me under my weight limit.

The best alternative I can come up with is a cast aluminum wheel from a really big road bike. Search ebay for "Virago Rear Wheel" to see what I'm talking about. I think one might be found with a big enough base diameter that a good machine shop could hog out the center, TIG weld on a mounting flange on one side, and some ears to accept another mounting flange on the other, and Voila! A much stronger rear wheel hub motor assembly. Then you would start thinking about the wheel bearings...

Just an idea.

In the next class larger trike, the most promising configuration is front drive, with a hub motor driving each wheel through a prop shaft. That would allow using a tiny auto front end just as it was designed, solving lots of problems and making for a really neat vehicle. If I were making a two- to four-seater, that's what I'd be doing.

BTW, TomB, nice work on the scooter trike. Must be a fun ride.

TomA
 
That scooter trike is a hoot!

btw, on the topic of front brakes, I diddnt think it would be true, but the quad brakes (from a raptor 600) are doing just fine, I am confident in them stopping up to 1000 lbs (trike and rider (s) )
 
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