Project Triebflügel! Fifth movie uploaded.

Clutch is repaired and reinforced (upgraded springs), it works well at 7A*75V=525W cont, 14A*75V=1050W peak. Default phase current less than 30A. I will probably use Redline DCTF (Dual Clutch Transmission Fluid) instead of the standard Biltema ATF (Automatic Transmission Fluid) I've used before. This is the absolute clutch power limit, as the Cwah said before. More than this is only possible by locking the clutch, ie using the brute and unelegant approach.

Cwah: No more wizardry please ;). By the way, what is the nylon gears power limit?

Oh no, it is having babies! :shock:
Dsc_0001 resized.jpg

The white frame to the left belongs to Mr. Wall Street, he was whining the whole sommer wanting one so I'm building it for him. It will probably became almost 1:1 copy of the Triebfluegel, as we ride together and he's sick of slowing me down:). The only difference is NCR18650GA cells instead of the PF ones (as those are discontinued). He is a very filthy old man not interested in airplanes and he will probably call it sexy lolita, gephard or something like that :D. That project started today ordering bunch of parts.

The black frame to the right is a Heavy Transonic Bomber prototype. I will allow its mass to climb up to 30kg, giving some very interesting possibilities of the motor and the rim choices. Target power is about 3.3kW at 2 x 92V, target speed 60km/h. It is likely that it will have to wait for the next generation of the Panasonic 18650 cells before I start that project (GA cells are the "half-generation" as I see it).
 
Thank you! My first "order" is almost finished, so there are two almost identical white Triebfluegels existing at the moment. I'm starting the work at the serial number "3", ie the Heavy Transonic Bomber project (design phase, black frame) as soon I sell my Interceptor ebike. I simply need more space in my garage, it has 4 ebikes at the moment. I've realised that I can ride one at the time only... :oops:

Any ideas and information about the suitable new motors are mostly welcome. Some ideas I have (brainstorming):
-Durolux 180mm fork instead of the Epicon 140/150mm. Possible problems: 0.5kg weight penalty
-2x92V idea is scrapped, I will use the multiples of 18s (75V) instead. 3x75V=225V or maybe direct jump to IGBT territory with 4x75V=300V later on? Who knows :D ?
-Bigger motor (Mxus 1000W or Mxus 3000W). Possible problems 10kg weight penalty. The sexier alternative is locked clutch and increased voltage to 150V, using the Q100H. Totally redesigned clutch with manual engagement maybe? Harmonic drive at 10000rpm from http://harmonicdrive.de ? Totally redesigned motor with new planetary gearbox and fulfill my 100000rpm dream? This feels like a 20 year project :roll: .
-Permanent aux battery pack hidden above the crank. Possible problems: Need for a 3D printer.

EDIT:New fourth video uploaded (mostly rejected clips that I wanted to publish before I erase those files).
Second prototype just hit 75 km/h at no load condition. I have no idea how or why :mrgreen: .
Note to myself:
MTI 85W100GC
MTI 145WX100GD
Allegro Microsystems A4900
TMPM370FYFG
TMS320F28026

Lastest LVC combo: http://www.falstad.com/circuit/circuitjs.html?cct=$+1+0.000005+10.20027730826997+50+5+43%0Ar+256+112+416+112+0+20000%0Av+416+384+416+192+0+0+40+49+0+0+0.5%0Az+256+384+256+224+1+0.805904783+3%0Aw+416+384+256+384+0%0As+256+112+256+224+0+0+false%0Ar+80+112+80+384+0+1200%0Aw+80+112+256+112+2%0Aw+80+384+256+384+0%0Aw+416+112+416+192+2%0Aw+928+112+928+192+2%0Aw+592+384+768+384+0%0Aw+592+112+768+112+2%0Ar+592+112+592+384+0+1200%0As+768+112+768+224+0+0+false%0Aw+928+384+768+384+0%0Az+768+384+768+224+1+0.805904783+3%0Av+928+384+928+192+0+0+40+53+0+0+0.5%0Ar+768+112+928+112+0+22000%0Aw+416+384+592+384+0%0Ax+88+34+209+37+0+15+ON1:+3.8V%3Cx%3C4.0V%0Ax+87+60+234+63+0+15+ON(13s):+3.3V%3Cx%3C4.0V%0Ax+84+84+231+87+0+15+ON(10s):+2.7V%3Cx%3C3.1V%0Ax+89+451+901+454+0+15+75V+hack:+3.0V+Zener+diode+and+20k+0.5W+SMD+resistor.+LVC=49V(2.7V/cell).+22k+0.25W+SMD+resistor+=%3E+LVC=53V(2.9V/cell)%0Ax+88+480+856+483+0+15+150V+hack:+3.0V+zener+diode+and+39k+1W+resistor.+LVC=93V(2.6V/cell).+43k+0.5W+SMD+resistor=%3E+LVC=102V(2.8V/cell)%0Ax+199+280+308+283+0+15+3.0V+zener+diode%0Ax+714+278+823+281+0+15+3.0V+zener+diode%0A

AC versus DC voltage by ElectroBOOM:
[youtube]hp97GjuULX8[/youtube]
Apparently, the votlage is what kills:
[youtube]XDf2nhfxVzg[/youtube]
170V DC vs 340VDC
[youtube]snk3C4m44SY[/youtube]
 
Report after one year:
The first prototype was generally extremly reliable, controller has almost all of its bugs solved and the batteries are working as a charm. Two smaller bugs remains, it needs 5 seconds delay after switching on without the LCD screen conencted, otherwise it stalls if I'm too quick to activate the throttle. Probably some capacitor value that need to get tweaked a bit to play nice at 75V/150V. Second bug is small oscillation at top speed when the LCD display is not connected. With LCD connected, it is a bug-free machine with a smooth powerfull power band from 0 rpm up to its 7k+ rpm.
-Changed 28t-13t freewheel to a 32t-11t DNP one.
-One puncture, on a very hard off road part in the woods. This was easily fixed without removing the rear wheel.
-Reinforced clutch

I am in the process of changing the nylon gears inside the Q100H to a titanium nitride, in order to use 150V and 14k+ rpm further on. I've removed the gears and will take them to a to a local company TiN experts. At the same time, fourth prototype is on its way. It is a red one:).
file.php


What happened to the other prototypes? Those are now in the possession of my friend, and knowing him it will probably end up on a ebay. This second picture is actually taken on a island, surrounded by the water. It was a water endurance test, that both ebikes passed without any problems. Lots of fun riding, water splashing everywhere. There are 2 almost identical ebikes on this picture (click for a bigger version), and people actually stopped us all the time to ask about what it was and where to buy it. :)
file.php
 
Nice project, it looks very professional.
I am in the middle of my own ebike project and was wondering about the NCR18650PF batteries, does all of them are as safe as you describe them? I see on the market some are offered as protected and other as not :roll: I am just following your steps and want to integrate the battery inside the frame, but there is no place for bms :))
I was also wandering if it's possible to connect the integrated battery together with another one, placed outside on the frame, and if so, should they goes in series or in parallel?
Thank you for sharing your thoughts.
Viktor
 
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