My new converted EScooter

[DeNew Lab]

Made in Chinese scooter (electric bicycle)

It was very poorly and crookedly welded... The battery was weak, and so was the motor, li-ion 20800mA 16S 60V and 500W motor.
All that was left was the fork and the head tube.
I decided to build my own. I've been working on it for six months now, all winter, and I've had little time for it.

I drew a little in 3D to understand, but it was only superficial.


Original scooter frame.


To create something you have to cut it off )))


Then, gradually, assembly and welding.
I didn't like a lot of things...Reworking.



New frame option.

 

[DeNew Lab]

Rear fork

Pipe 40x20x3mm. dropout on laser 6mm steel.

 

[DeNew Lab]

The frame is almost finished.


Footrests, side and etc. )))

 

[DeNew Lab]

Key for the seat.

 

[DeNew Lab]

All the electrics are under the butt.


There are a lot of wires going to the panel.

It has everything you need: time, engine temperature, ECU, voltage, etc.
I designed the printed circuit boards myself, including the power board and the dashboard board.


Block diagram of a scooter.

 

[harrisonpatm]

All the electrics are under the butt.
View attachment 384828View attachment 384827View attachment 384826

There are a lot of wires going to the panel.
View attachment 384829View attachment 384830
It has everything you need: time, engine temperature, ECU, voltage, etc.
I designed the printed circuit boards myself, including the power board and the dashboard board.
View attachment 384832

Block diagram of a scooter.
View attachment 384831

Very organized, looks good!

 

[SlowCo]

What an awesome build. Curious to see what the final result and performance will be.

 

[DeNew Lab]

Thanks, guys! I'm really interested in this; it's a really long process. I'm not aiming for an Oscar ))) but I love making my own...

The front (90\90) and rear (110\80) wheels are 12 inches with 16-inch Mitas tires.
Hydraulic brakes all with 220 mm discs, standard 84 mm calipers, but the rear brake is foot operated.


I made the battery last year.
My new battery LiFePo4 20S3P

 

[j bjork]

Nice
And the wiring diagram that usually never get drawn properly, and later you are scratching your head trying to remember how it was wired

 

[DeNew Lab]

And the wiring diagram that usually never get drawn properly

I don't even know where this important part is, it's not that hard for a scooter manufacturer to do, but China doesn't give a damn about it I hope they won't be offended
I don’t remember what I drew anymore, especially since it’s a 20-core cable, it’s not colored, just numbers....

 

[DeNew Lab]

I've already planned it out and will do it: when you stop, I fold down the side stand and... And then the scooter goes into park mode and the hazard lights start flashing. It's a relief not to have to worry about it, especially if the police stop you


In the diagram, this is an inductive sensor.


PCB





Probably few people noticed the appendage welded to the leg.

 

[bananu7]

Very nice build. You're posting well into the project, which is quite rare. Hopefully it'll ride before winter!

 

[DeNew Lab]

I spent a little time today on the trim. It's ABS plastic and stainless steel of varying thicknesses from 0.5 to 1 mm. Screws and glue are also needed. The brake pedal isn't fully welded yet. It looks rough, but aerodynamics are hard to do at home... The glass is made of fiberglass, and the polymer resin will be used in the next life ))))))



The rear brake is foot-operated, as I already mentioned, it's more convenient for me...
I chose this hydraulic cylinder.

 

[DeNew Lab]

I had to add a sensor to the brake pedal.
Hydraulic switch, triggered when the brakes are pressed very hard ((


The scheme has been changed.
View attachment 385802View attachment 385803

 

[DeNew Lab]

I assembled the panel based on the ECU.
Since the engine is different and my controller isn't large enough, I'll buy a different one, probably a 100GTS.

 

[DeNew Lab]

The insides of the ECU Votol EM 100-2 GTS.


The photo is not mine, but from our forum, nicknamed Oclipper.
Votol EM 100-2 GTR

 

[DeNew Lab]

Test brake disk )

 

[DeNew Lab]

The new EM100 ECU arrived.

It works very well, clearly more powerful than the EM50.
And since it doesn't have a CAN connection, but a UART, I'm returning the Bluetooth module. It will always be connected over the air, and can be configured on the computer.

 

[DeNew Lab]

Test ECU EM100 GTS, current set to 60A, i don't want to drain the battery in 5 seconds )))
Battery not fully charged (76%).
Battery consumption 4144.1W -64.8A, voltage drop 1.13V.


The current in the program is correct; after stabilization, the current is the same, the peak current is 64.8A, this is without load.

The motor has two temperature sensors.
1. The original sensor is 38:Ext_temp_KTY83_122
2. I installed 53:Ext_temperatrue_MF52_103_B3380
The program shows the temperature as 42 degrees, which is incorrect; it's 8 units lower. The sensor is lying.

 

[DeNew Lab]

I've completed the project and evrything works great 9 mounts of work...



Video