Suzuki RG250F Gamma conversion

14 teeth on the front, 47 rear. It's tall, for sure. But I found the 12:47 too low. The no load speed at 6000 rpm is 212 km/h, which is quite reasonable given it will spend a lot of time 25% slower than that. No point going for a crazy top speed on a race bike, but I don't want it screaming silly either.

60 teeth!! How big was your drive sprocket??
 
jonescg said:
14 teeth on the front, 47 rear. It's tall, for sure. But I found the 12:47 too low. The no load speed at 6000 rpm is 212 km/h, which is quite reasonable given it will spend a lot of time 25% slower than that. No point going for a crazy top speed on a race bike, but I don't want it screaming silly either.

60 teeth!! How big was your drive sprocket??
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15 front, geared to around 180kph. Any higher lost us too much torque and makes the peak power duration much longer risking overheating/brush damage. Of course the ambient temperature in the UK (15C) is much higher than Oz, so maybe you'll be OK;)
Is your racetrack all straights?
:)
 
Well to be fair I did design it with Wanneroo Raceway in mind, which has three long straights and a handful of turns in between.

I also have a 54 tooth rear, which gives me about the same final speed as yours, so I can try both at the circuit on Friday. Yep, I was feeling pretty shagged by the end of it. Last nights stubbies went down like a well paid harlot :)

Now, if some other Sydneysider wants to show me how to make a good fibreglass tank cover, go right ahead :D
 
Hi all, so voltron does 177 km/h down the straight and handles pretty well- except I have cooked one of my motors when I pushed it to 180 :(. Seemed perfectly fine pulling 750 amps battery side but 800 cooked it. The other motor is perfectly fine! so does anyone in Sydney have a spare Agni?? Did really well otherwise
 
BAD Chris, 800A battery side in a race situation is too much (as you've discovered), it means you have fed over 400A per motor at maximum speed (more like 600A at lower speed tailing off to 400A at top speed, and even then I'm assuming that the motors were balanced very accuratly).

I've asked a friend of mine in AU if he can help, he has a few motors and is based in Sidney.. I've directed him here..


Hope you get it sorted in time for the action!

Steve
 
jonescg said:
Hi all, so voltron does 177 km/h down the straight and handles pretty well- except I have cooked one of my motors when I pushed it to 180 :(. Seemed perfectly fine pulling 750 amps battery side but 800 cooked it. The other motor is perfectly fine! so does anyone in Sydney have a spare Agni?? Did really well otherwise
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I am not surprised that one is burned, the other is totally fine. I haven't read this entire thread, but brush timing is really critical, a fraction of a millimeter rotation of the brushes can be the difference between 400 amps per motor, and 600 amps in one motor and 200 amps in the other.

You need to spend time with current meters on a motor lead to each motor and measure them at the same time, adjusting the brush carrier of one motor until they both pull about the same amps at high current draw. 400Amps into an agni should not be a problem for short periods.

-ryan
 
Voltron's new motor held together today with some of the Kelly controller's settings turned down a bit.

Chris came second today and the bike lives to fight another round tomorrow.

I've attached a photo I took from the track. Most were blurry unfortunately.
 

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Excellent news...
 
Jozz - I wrote reply to your PM but managed to lose it all somehow :lol:

We did get the replacement motor from Peter - got it in with the help of Ripperton's workshop and Aberaham's help. We dialled the controller back to 70% and I could still get 170 km/h on the straights and maximum battery side draw was ~650 A, so it's behaving itself. The brushed aren't wearing evenly which is a concern for tomorrow's race but I'd rather take it eeasy and come last than destroy another motor.

Currently doing well :D
 
Dailed it back to 70? Didn't I reccomend starting with 65%?:D
To balance is as simple as applying power and measuring current, though it helps accuracy to do it with as much load as possible.. (ie, Dyno better than paddock stand!)

Steve
 
Some of Mark's footage from the weekend
http://www.youtube.com/watch?v=5Vw4Uv_fsw4&feature=feedf

A video of me as I break down soon after completing my first lap :(
http://www.youtube.com/watch?v=qT89CLf780w
 
Some more pictures from the weekend's efforts:

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The silver splatter on the inside of my fairings was the tears of an Agni motor who got too many amps.
 
Hi All,

Well I have decided to finally parallel my three battery chargers so I can bulk charge Voltron in 2 hours from dead flat, instead of 6. Not that the extra track time would have done me much good (I would have still burned out the motors, just sooner :lol:) but since I'm riding a new track each time I might as well get as much time in the saddle as possible. I have two here, and the third one is still in Canberra with SplinterOz.

ebikeshedstuff003.jpg


These Elcon chargers were purchased from Rod Dilkes at http://www.EVpower.com.au, who gets them from Nancy at TC. They leave the factory dialled in to whatever voltage you choose (117 V in my case). The other cool thing is the charge enable plug, which is really just a circuit that turns on the charger. Rod's BMS master unit has a 'normally on' relay so that should one of the cell modules record a very high voltage, it will trip out and make this charge enable circuit open circuit, switching off the charger. When you have three of them in parallel, you need to devise a means to turn them all off or on at once.

Rod gave me a mud map of how to do this. Basically you have three SPST solid state relays where the activation coils are wired in parallel. The individual charge enable leads are wired into the output terminals of the relays. The activating circuit needs 12 V, so you have to apply 12 V through the same circuit.

Below is the mud-mad Rod drew for me, I found it very helpful.

Also, I have started to bog up the original tank I have for the RG. Someone has offered to fibreglass me a cover, as the polycarbonate one I have currently is not exactly ergonomically sound. The knee-divots were too narrow for the tank to fit over the battery packs, so this should fill it out a bit.

ebikeshedstuff004.jpg
 

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OK, attempt number two at fibreglassing a new tank cover for Voltron. I'm using the original, metal petrol tank as a plug. I did cut the base out, but unfortunately the knee-divots are too narrow to fit over the top battery packs. So I have bogged up the divots and started to fill in the filler cap and other bits which will make removing the mould difficult. I think the sides are done, it's just a matter of smoothing off the top and covering it all in epoxy. Now, for people who have lots of experience with bespoke moulds, please let me know what I need to do to prepare it for mould making. I don't have the patience to do it a third time... Spray putty? More expoxy? 9000 grit sandpaper and polishing compound? I'm thinking of giving the final plug to someone else and hoping they can do it for me.
tankcharger002.jpg


Also, I have started to put the plugs together for my three paralleled chargers. I'll probably just put all three cables into one via a bus bar or something similar, otherwise a shitload of solder and heat shrink to hide the mess :)
tankcharger001.jpg
 
I finished the paralleled charger, triple-adapter. All I need to do now is get the new tank cover made.

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http://www.canberratimes.com.au/news/local/news/general/canberras-interest-in-electric-cars-sparks-up/2250950.aspx

SplinterOz kindly displayed my bike at the Canberra "Engineering Week" festivities :)
 
Just to let you know, no matter what the article say's I did not claim ownership of the bike. :mrgreen:

The interest was great over the course of the day. Many informed questions.
The paper has a quarter page photo that I will scan and put up.
 
The press? Get things factually correct?? :mrgreen: :mrgreen:

Nah, all good :) Sounds like Canberra has a very active EV crowd... Fantastic :)
 
Dammit! Daniel has been in the shed and on the track again :lol:

[youtube]uzHUcvzHJVU[/youtube]

Looks like he has a sound setup. Hopefully I can source some sticky tyres and a faster rider :lol:
 
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