Super hiryuu - A BBS02 / Leafmotor / MXUS 3kW Dual sus. bike

I wish someone would have told me about the whole 'no power potential' thing the couple times i mentioned buying one and pumping up the power. Oh well :p

Stock power isn't so bad, but the controller still irks me. What i do in between shifts is hit the brake lever slightly to get the controller to back off. PAS on offroad is really dangerous because of the 2 second offset between on and off. I have to constantly change the assist level from 1 to 0 on real rough terrain, otherwise the bike is going to do something i don't want it to do. This is a real bummer.

I really hate PAS. I also hate holding down a thumb throttle. I like the variable amps on the controller a lot, versus an infineon controller which would be fixed. Totally torn on what to do.

I love this bike on offroading. It's pefect and handles like i'd expect a nice dual suspension bike to perform while rolling over rocks and logs and stuff. I took it out into some wilderness and it was a real hoot. My hardtails with hub motors were just punishment to ride in the same situation, by comparison!
 
Hi Kepler, thanks for chiming in. The main thread and the programming threads are a bit of a mess and full of information that seems to be hit or miss. You seem to know the most..

So while i have you..

There are dozens of USB TTL thingies that have been recommended on the programming thread, i can't sort out which is best.. what should i buy anyway? here is my model #:

hiryuu10.jpg


Also, is it possible to program out the delay for when the power cuts out... it seems to take an entire second for it to turn off when i stop pedaling. Very annoying.
 
neptronix said:
I wish someone would have told me about the whole 'no power potential' thing the couple times i mentioned buying one and pumping up the power. Oh well :p

Nep, we all figured you would be the man to squeeze the last W out of this drive and see what it could really do :twisted:

neptronix said:
Stock power isn't so bad, but the controller still irks me. What i do in between shifts is hit the brake lever slightly to get the controller to back off. PAS on offroad is really dangerous because of the 2 second offset between on and off. I have to constantly change the assist level from 1 to 0 on real rough terrain, otherwise the bike is going to do something i don't want it to do. This is a real bummer.
My drive starts and stops almost instantaneously with PAS. It can be improved through tuning.
I use my bike single track all the time. I leave in the lowest PAS setting when off road most of the time and use a boost button that gives me about 600W when I need it. moving the gear lever slightly (just through its free play before it actually selects) activates the microswitch which applies 1.5V to the throttle signal. This instantly stops the PAS and allows the crank to turn just fast enough to softly shift gears if needed. Works a treat.
neptronix said:
I really hate PAS. I also hate holding down a thumb throttle. I like the variable amps on the controller a lot, versus an infineon controller which would be fixed. Totally torn on what to do.

I love this bike on offroading. It's pefect and handles like i'd expect a nice dual suspension bike to perform while rolling over rocks and logs and stuff. I took it out into some wilderness and it was a real hoot. My hardtails with hub motors were just punishment to ride in the same situation, by comparison!

Get the PAS setup right and it might just change your mind. :wink:
 
I appreciate the vote of confidence and see why you wouldn't want to discourage me from doing it :)

I just realized something. I have the old 6FET controller, looking at the production date.
That genuinely sucks.

That's another vote for an external controller. Maybe i just run this one until it blows and use it's casing guts to form some kind of basis for an oil-pocket or some type of fan to bolt on the motor, or just hollow the thing out.

I may do something lame though and keep mine at a 20A limit but experiment with 110%-120% modes :)

I still like your ideas with PAS a lot though. It's ideal for this sort of thing. I saw someone hook up a regular PAS sensor to it to bypass the stock.. seemed legit, if you can tune it correct with an infineon controller.

Have you done your magic on an infineon setup before, kepler?
 
ypedal you ar right, i am getting the hang of the shifting, but it's annoying.
I drive a manual transmission car and always have. Driving an automatic drives me batty. That's kinda what this system is like.
 
Hm... what about a kelly controller ( torque control - hey! ) or a BMSBattery sinewave controller as a replacement for this 6fetter?

The BMSBattery controller has settable levels of assist and torque control apparently?
Seems ideal as a mid drive controller... even if you just use a throttle..
 
I ordered it recently, but didn't know that i was getting an older model..


Uh so... Anyway..
I got real excited about riding it today and put like.. an hour and a half on the thing; up and down hills of all kinds of grades.

I managed to get a whiff of stator near the end of the ride :(

I think there is a genuine problem with running it on 12S, at least on my battery that sags by an entire volt ( wimp-ass 15C zippy lipo that is more like 7C in reality ). The pedaling cadence is too low, and this means that i put very little power into the motor. Running it on the highest assist level increases the cadence to closer to an acceptable level, but also beats on the motor.

I only hit an acceptable cadence while in far too low of a gear, or going downhill. This indicates to me that i have to basically 'pedal over' that 80% loaded speed.

Will have to increase the voltage and lower the amps..
 
I've read that Bafangs next move is producing a torque-sensing version (BBT01, BBT02). How soon, and how good will it be? No way to know. In theory it should be a much smoother transition to power on and off, with almost no delay, but...I guess we will have to wait and see.
 
They had better release it soon, other companies have already developed a more integrated torque sensored mid drive, like Sunstar with their Virtus bolt on kit.

EDIT - only Bafang torque sensor BB drive I have seen is the one on the Eurobike thread and it requires a custom frame like Bosch
 
Torque sensing, rather than this silly 2 pole PAS business would be fantastic.

I'm at a bit of an impasse right now; i don't know the pole count of the BBS02 motor or the RPM. The kelly controller is a bit of a slowpoke at 40,000 erpm.

Anybody know the poles and RPM of this motor by chance?

If not, i have to wait until next week, because we have the earth fair and EV fair and i have an electric bike to show off... not tearing it apart to find out, until after.
 
Okay, Kelly KBS48051EL ( 30A / 48v ) controller is on the way.

I popped the controller off tonight to see what i would be dealing with, and the external wiring job looks easy, other than having to play 'guess the hall-phase correlation'... lol.

I pulled the gray wire on the 4 pin connector to disable the PAS on the stock controller for now. After riding it, it seems a lot more confident and controllable being a throttle-only type deal.

Couldn't get it to do the whole 'pulsing at the crank' thing that happens often with PAS either, even at low rpm. Nice.
 
neptronix said:
Okay, em3ev kit here and i get no throttle when the assist level is set to 0, sadly.
Paul says that they're programmed to run on throttle with the assist level set to 0, but that's not happening for me.

I'm finding the same issue with the July updated 25A kit via Paul, my throttle acts like an on/off switch, doesn't run throttle in 0.
I've tested on the fluid trainer with and without load, it breaks traction leaving a white line in 2nd gear (48/13T) which invokes some giggly fear for when I take it to some dirt =D
The PAS levels from 1-3 changed to 1-9 don't seem to do anything different 4-8 at 22kph, then crazy throttle in 9, but I'll wait til I'm on the road to test under real loads.
The walk mode is a nice idea, would be nice to be able to program it to throttle in level 0 for on-bike use in one settings profile for tight traffic control areas, and have another profile for offroad or easy access areas.
 
So Nepi, give us your verdict?
You are one of the few people who owns both a MAC and a BBS02, which is very interesting to me, as I'm debating. After the teething problems, now that you've been riding for awhile, which one is it? Give us your comparison impressions.
I saw in a video of yours that you bought the BBS02 because you "moved to a very hilly are". But, in older videos, I saw you take some really long, pretty steep grades with the 10T at surprising speeds! So I'm wondering: was the BBS02 really necessary, and how did the BBS02 hold up to the comparison and expectation (including quality-wise)? Was the BBS02 (stipulation: with the original controller) in the long run an upgrade, or a downgrade?
What I'm most interested in: were there hills you couldn't get up before without pedaling on the 10T, that you can on the BBS02?
Less importantly, what's your comparison of Watt-hours per mile?
Thanks!
 
You can go up any grade you like with a BBS02 (even if you weigh 218lbs like me).
All it takes is the right gearing.
I currently have a 46T chain ring and a 28 tooth rear low gear and can get up a 10% hill on throttle alone.
Got an 11-30 T freewheel coming so be interesting to see what grade I can do with this.

As far as gear changing goes I just stop pedalling for less than a second and the motor cuts out then change gear(usually 2 at a time) and the motor cuts back in within a third of a revolution.
On the flat at low speeds it will change gear under power smoothly enough without backing off at all.
 
Kepler said:
neptronix said:
I wish someone would have told me about the whole 'no power potential' thing the couple times i mentioned buying one and pumping up the power. Oh well :p

Nep, we all figured you would be the man to squeeze the last W out of this drive and see what it could really do :twisted:

Oh come on, I took a shellacing for using the phrase soggy when I warned you!
 
Sorry - I should add that these things really do sip amps, if you want a highly efficient mountain climber you should do it.

I still prefer my geared rear hubs being flooded with amps, but that's just a personal taste. There's no real answer to preferences!
 
Hi sprock;
I had a 8T and it was quite good on the hills indeed. I would say that the MAC is a stronger motor for sure. What the BBS02 has over it is that in a dual-suspension setup, you have the motor weight neutral and not being unsprung mass, so it doesn't really interfere with the suspension action of the bike.

My back and many joints are still questionable after my crash, so building a bike that floated along the road without upsetting my body was also a priority, and the BBS02 fit the bill.

I can't tell you about the quality yet! i've put quite a few miles on this kit and haven't had problems.. The MAC 8T lasted me over 3 years, and honestly i kinda want another.... lol.

What the BBS02 has going for it is that i am able to modulate the power per situation, and not worry about it overheating on a long constant climb ( we have lots of those here ). The 8T MAC did that often, and as a result i drove up the kV of the motor by weakening the magnets during periods of intense heat soak. So i lost efficiency doing so.. and figured that if i just ordered another, i'd end up with the same problem.

The MAC is certainly more powerful. If where i live now didn't have the geography of a rollercoaster, i'd have picked up a 10T MAC and thrown some volts at it.

For now, i am trying to heal my back with various posture correcting methods and stretching.. i just haven't had enough pain-free time to work on doing the external controller wiring & stuff.

wh/mi is really good if i 'take it easy'.. low 20's at ~20mph? I couldn't compare it to the MAC, as my MAC had been demagnetized for a very long time.. sorry!

SprocketLocket said:
So Nepi, give us your verdict?
You are one of the few people who owns both a MAC and a BBS02, which is very interesting to me, as I'm debating. After the teething problems, now that you've been riding for awhile, which one is it? Give us your comparison impressions.
I saw in a video of yours that you bought the BBS02 because you "moved to a very hilly are". But, in older videos, I saw you take some really long, pretty steep grades with the 10T at surprising speeds! So I'm wondering: was the BBS02 really necessary, and how did the BBS02 hold up to the comparison and expectation (including quality-wise)? Was the BBS02 (stipulation: with the original controller) in the long run an upgrade, or a downgrade?
What I'm most interested in: were there hills you couldn't get up before without pedaling on the 10T, that you can on the BBS02?
Less importantly, what's your comparison of Watt-hours per mile?
Thanks!
 
Oh my gosh Nep, I didn't realize you got THAT jacked up on the crash. I assume this was the one where your tire fell into the train track rut.

An unsolicited suggestion... try just being on 'all fours', on a bed is fine, and relax in that position. It can help put a back 'back to normal'. I then usually shift my weight a little front-back, side-side, diagonal, in a subtle not quite rocking motion. Helps me a lot. I feel little cracks and flexes when I do that, too. It's easy to do, unlike some exercises. The other thing that helped me the most was a "Back Nobber" which you can get on Amazon, and it's priceless if you have or can discover pressure points that you respond to really well. I recommend the simpler rounder-pointed Back Nobber over more pointy mimic devices which have more 'knobs'. These two things helped me more than the exercises given to me by professional physical therapists, and neither came from them.

Well I had no idea that the 8T was in "demise" status, nor that it was from demagnification or de-gaussing from heat. I've actually never heard of that. I suppose you never did the Trans Oil trick. THANK YOU for the excellent analysis. It was actually kind of what I was expecting, and confirmed a bunch for me.

So impart some advice to me: how do I best "get the most out of a MAC", yet still avoid damaging it? Mainly in terms of programming and amp limiting. You've pretty much explored where the limit is. I know you've pumped over 4KW at some points into it... and Cel-Man wouldn't approve of me doing that :) . I think the faster wind of your 8T is also more prone to overheating, and... I think you may have had the older version (I know you had white gears) with thicker laminations, which was also more prone to overheating, particularly at higher voltages? Do you know what the 'saturation point' for this motor is BTW (just starting to learn about these things). If I decide on a MAC, it would be a 12T for me, because I ride slowly, normally fairly flat, but may occasionally may do steep and/or long hills. I'm planning on a hardtail for now too, and already have 72V worth of Multistar 10Ah battery packs, 48V of which I can already use on my cheapie ebike, as I do research for a real DIY setup.

Thanks Again. And hope you feel better soon, truly do.

Sprock.
 
SprocketLocket said:
Oh my gosh Nep, I didn't realize you got THAT jacked up on the crash. I assume this was the one where your tire fell into the train track rut.

An unsolicited suggestion... try just being on 'all fours', on a bed is fine, and relax in that position. It can help put a back 'back to normal'. I then usually shift my weight a little front-back, side-side, diagonal, in a subtle not quite rocking motion. Helps me a lot. I feel little cracks and flexes when I do that, too. It's easy to do, unlike some exercises. The other thing that helped me the most was a "Back Nobber" which you can get on Amazon, and it's priceless if you have or can discover pressure points that you respond to really well. I recommend the simpler rounder-pointed Back Nobber over more pointy mimic devices which have more 'knobs'. These two things helped me more than the exercises given to me by professional physical therapists, and neither came from them.

Yup, that's the one where the tire fell into the train track.

It's funny you mention back positioning. I had just read about that. Apparently there is a huge correlation with back and neck pain and posture. I looked at my spine, and it is crooked from being a total computer nerd / internet addict since 1994 ( i'm 32 now ). In fact, most people have this slouch in their neck and back because everyone is using a TV, mobile device, computer etc for half their waking hours or even more. We are in for an epidemic of back and neck pain soon in the advanced world.

I have learned that the key to eliminating a lot of my problems is how i hold my body and also in muscle training. I am looking into doing tai chi or yoga very soon as winter sets in. In the last week, i built a standing desk and attempt to hold my posture as well as i can. It has made a huge difference in my level of pain. I am already more functional in just 4 days. Amazing. If a few people can 'pop' slipping and herniated discs back into their spine with motion, and others can correct chronic pain simply with posture, i can do it too.

I think after my crash, i made a mistake and stopped moving, thinking under the lines of the conventional thought where 'if you just stay off it, it'll heal'. I've learned that conventional medical wisdom is often wrong. It is not based on results, it is often based on profit for the provider, it seems. I think the Asian and Indian societies have this figured out far better than we do anyway.

I have a lot to say on this topic, but i'll stop now. Thanks for your recommendation on the back nobber :) I hope you are doing better as well.

SprocketLocket said:
Well I had no idea that the 8T was in "demise" status, nor that it was from demagnification or de-gaussing from heat. I've actually never heard of that. I suppose you never did the Trans Oil trick. THANK YOU for the excellent analysis. It was actually kind of what I was expecting, and confirmed a bunch for me.

So impart some advice to me: how do I best "get the most out of a MAC", yet still avoid damaging it? Mainly in terms of programming and amp limiting. You've pretty much explored where the limit is. I know you've pumped over 4KW at some points into it... and Cel-Man wouldn't approve of me doing that :) . I think the faster wind of your 8T is also more prone to overheating, and... I think you may have had the older version (I know you had white gears) with thicker laminations, which was also more prone to overheating, particularly at higher voltages? Do you know what the 'saturation point' for this motor is BTW (just starting to learn about these things). If I decide on a MAC, it would be a 12T for me, because I ride slowly, normally fairly flat, but may occasionally may do steep and/or long hills. I'm planning on a hardtail for now too, and already have 72V worth of Multistar 10Ah battery packs, 48V of which I can already use on my cheapie ebike, as I do research for a real DIY setup.

Yes, i had beat the bloody hell out of the MAC over the years. Most of the abuse happened when i was 270lbs. The little 4kW stint structurally weakened the original white gears and they turned to peanut butter days later, but was part of the overheating of the motor. That, plus climbing super tall grades on 36-57v. After i found out that it was demagnetized, i didn't stop abusing it. I would run it on 36v and 120% mode, hitting a top speed of 38mph with pedaling. It had turned into something like 7T motor by the end, lol. I sold it with a notice about it being demagged and honestly have kind of missed it since. Now, the newer versions have higher efficiency due to thinner lams.

Go with a 10T if you have mostly flat land. Adjust your voltage accordingly. The BMC V2 'torque' on the ebikes.ca is a 10T MAC equivalent winding, by the way. The speed BMC V2 is an 8T.

If you don't have more than 5% hills, an 8T MAC is fine if you are a lighter rider ( under 200lb ) and are using a 26" wheel rather than a 700c.

As far as promoting longevity of the motor, i know something about that. On my 8T, i ran a em3ev controller at a lower phase ratio than the controller came shipped. I ran around 2.4:1 phase:battery amps. Default is maybe 2.66:1-3:1. So in other words, say 24 amps phase, 10 amps battery ( multiply that upwards to taste ). This forced me to pedal from a stall by tuning out some of the initial torque of the motor ( and it does have a hell of a lot ), which reduced heat buildup in stop 'n go and also made my clutch last the entirety of my ownership of it, despite major abuse.

It is that initial hit of torque from a stall that really beats on the clutch. So detuning the phase amps a bit lowers that hit quite a lot. Yeah, it's not as fun because you can't blast off the line as hard, but your drivetrain and battery watt hours will thank you.
 
Well, i just completed a major ride up cottonwood canyon here in Utah. I ran the BBS02 at 25% power ( setting '1' ) up a continuous 7% grade doing about 14-15mph while pedaling. The motor became hot to the point of me being able to smell the stator within a few miles. Then i shifted down to a gear that does 9mph and it was able to hold that speed continuously without giving off the stator smell.

This road is so constantly tall that the average bicyclist would be walking up it instead of pedaling. If this gives you any idea of how steep it was, i hit 50mph on the downhill without much effort. I had never gone that fast on a bike all my life. This is basically like climbing up pike's peak in Colorado ( but prettier!!! )

Most hub motor setups would have turned into plasma halfway in. I turned back after climbing ~3,600 feet because i was worried about the small battery i was carrying ( range anxiety! ). When i came home, after the 26 miles, i had used just 12AH of my 12S 14AH Lipo pack. Not bad at all.
 

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