Nissan Leaf motor at 60V, 1/6 the power?

[yabert]

So fun to work with high quality stuff.

It's so tempting to fit a Tesla 3 hub (trust bearing) directly on the motor spline
That imply a ''magical'' spline to spline adapter (male/female).
So, metal 3D print, laser cut 10-15 splined plates or rework of the Leaf spline gear?

 

[harrisonpatm]

I came across a too good to be true deal and I couldn't resist.
I now have two 2019 Leaf motors in stock to do some testing

View attachment 376361

May I ask what the cost was?

 

[yabert]

May I ask what the cost was?

500$ CAD for both.

 

[harrisonpatm]

500$ CAD for both.

That is a great deal

 

[yabert]

I've change my mind the minute I saw the internal components of the transmision.
I will be able to reuse the female spline shaft with the bearing and connect this directly to prop shaft of our boat.
The ball bearing will take the thrust from the proppeller as:
-Large deep groove ball bearing can take an axial load roughly 50% of their radial load, so over 3000 lbs for this bearing.
-I've read 20 lbs per HP rule of thumb for propeller trust, so never over 400 lbs here.

Now, I need a manner to test if this motor can output 10 kW at 60V.
I've ordered a VESC 75/300.

1-I thought about create a load with a disc brake and a caliper. Will generate lot of heat fast
2-Fix a plane propeller to it. Many unknow here, lot of noise and danger
3-Build a dyno with Leaf/VESC 75/300 on one side and ME1507/BAC2000 on the other side. Lot of unknow and good result can be complex to obtain.
4-Other idea???

Let me know.

 

[arber333]

Hah, you already have two ! Leaf motors. Simply make a coupler between motors and use one motor in regen mode with one inverter and battery and use the same battery to power your testing inverter.
- You need two inverters
- You need a coupler between both shafts
- You need some form of direct DC current and voltage recording and measurement

First motor should be run as generator and provide resistance on demand. You could easily use Lebowski drive in sensorless for that... or can use VESC in sensorless mode apparently...
Second motor you can use VESC in whatever mode you want to test it. You should get your energy/power transfer minus electrical losses...

 

[A-DamW]

3-Build a dyno with Leaf/VESC 75/300 on one side and ME1507/BAC2000 on the other side. Lot of unknow and good result can be complex to obtain.
4-Other idea???

Here is a VESC based two motor dyno:

Links:
Joule Motors
Brushless motors, 3Phase inverters, schematics. Joulemotors.com

 

[yabert]

Sure, build a dyno make sense. Especially since I can use a ME1507 motor or even a 10kW Golden motor to test the Leaf motor.
And the mechanical part of building a dyno don't fear me... but the control of it fear me way more.

 

[eee291]

I think you're not going to get much usable Power using a flipsky and such low voltage. I've tried with the Hyundai hsg, on take off it just jolted and cut out for a while. It did run well without a load though.

 

[yabert]

you're not going to get much usable Power using a flipsky and such low voltage

It's why I would like to bench test it... with a VESC.

 

[SlowCo]

Really nice deal on those Leaf motors. Curious to see if it will work and output the desired torque and power.

 

[yabert]

Curious to see if it will work and output the desired torque and power.

Dyno design with ME1507 motor in progress.
Leaf and VESC 75/300 on one side and ME1507 and EZkontrol 1500A on the other side (as ASI BAC 2000 is not powerful enough, I think).

Motors RPM/torque don't match well, but I guess the ME1507 can suffer 10 seconds overload of 100-120Nm at 800-1000 rpm.
Maybe

 

[yabert]

What kind of power I can expect at 60V?

For those smart people who know the answer, it's time to wake up or stay mute forever because...
Here is the adapter to fix two motors and I will order material soon.
It's design to fix a Leaf motor to a ME1507 motor, but also a Golden 10 kW motor or another Leaf motor

 

[A-DamW]

Here is the adapter to fix two motors and I will order material soon.

Oooh, nice!

What material? steel, aluminum? Will it be welded together?

Either way, the interlocking tabs look to be quite stout

 

[yabert]

Aluminum 6061-T6, 1/4''.
TIG weld.

 

[yabert]

VESC 75/300 controller: how I program in on a PC?
VESC tool is only available for Android (forget Mac)?
How I run all this on my PC?

 

[scianiac]

VESC PC you download from VESC website, bottom of page: VESC Project

Yes you need to add one to cart, kinda weird but it is a way to do a donation system that works.

 

[yabert]

Yes you need to add one to cart

Thanks. That work.
Strange, but finally find vesc tool for pc.

 

[yabert]

First spin of the Leaf motor today with the VESC 75/300.
Not much control, no real result, except info from VESC. Is that give something about potential power at 60V?

 

[johansen]

I would not trust the motor bearing to handle the prop shaft directly.

shock loads of hitting something are in the thousands of pounds or even ten thousand, of course that depends on your propeller yielding.

consider using a car's steering wheel crush bellows coupling. or use a cross groove CV axle to couple the motor to the prop shaft bearings (assuming its below the water line) -this allows for axial shift on the order of 2 inches.

I personally have a small boat and i'm intending to fit a 20" diameter propeller on a 10hp diesel engine, geared down to match the engine rpm to maximize efficiency.

while its nice to have an electric drive, i like redundancy and want to be able to directly drive the prop from either the engine or battery, or both if needed to make way up current and against the wind.

 

[eee291]

The flipsky or any vesc really will struggle to just run any high voltage motor on auto detect. You will need to manually tune the settings.

 

[yabert]

I would not trust the motor bearing to handle the prop shaft directly.

Absolutely! The plan it to have a 5000 lbs rated bearing who take the load and the motor shaft only give torque via splines coupling.
As you can see details post #30.

 

[yabert]

You will need to manually tune the settings.

Do you have advices?

 

[yabert]

I will need an encoder for the Leaf motor as I read resolver are pain in the ass. On another thread, I saw suggestion for MT6816 or AS5600.
Any other suggestion?
I'm a bit lost at all this as I can see encoder for sale at 1.42$ on Ali or 25$ + shipping at other place or even 2 for 12$ on Amz... Where to find a correct one?

 

[eee291]

AS5047P

https://a.aliexpress.com/_EyOLUxg

You can also run the motor sensorless.