TREK+VIPERA electric (DONE-HDVIDEO) June-30

[sirhaxalot]

UPDATE Bike is done, will commute to work, and add data from my tracks, still waiting for watt analyzer

Here is my electric bike project and pictures so far.

Bike
2012 - TREK 4300 DISC 26"

Motor
Conhismotor 26" wheel
48v 1000w controller (set to 30 amps 1440w)

Modifications
Red button (power switch) on thumb throttle switch is rerouted to Delta-WYE 3DPT relay.
New powerswitch for controller on alu casing.
Delta-WYE mod - a 3DPT 30A relay (will give around 60% increase of speed and 60% less torque)
Teoretical calculations -
NO LOAD WYE 480RPM 50-55Km/h LOAD WYE 40-45Km/h // NO LOAD DELTA 88Km/h LOAD DELTA 60-70Km/h
Real results : NO LOAD WYE 58Km/h LOAD WYE standard configuration average speed 45-50Km/h on flats.
Have not implemented delta-wye relay yet, results will arrive when this is done.

48V universal stepdown converter 12V10A - Working input from 30-60v
This will be for among USB charging and other 12V equipment.

Legal speed issue
Modification to throttle input on controller, "deadmans pin"
When little pin is taken out of the thumb throttle, maximum throttle value will be lowered to almost nothing on input of controller.
Pin out = Road use LEGAL .... Pin in = maximum speed
I will try to achieve this with a springswitch and a resistor circuit inside of the thumb throttle.
Havent yet done it but it should work. (done, did work)

Batterypack
LifePO4 38120 (flatbed) x 16Cells 51v 10ah
Battery management system for 16S

Batterybox
Made of aluminium, first i made a template of the frame hole, then made the side covers,
went to a metal sheet workshop and made a U profile with inner diameter of 80mm (twise the width of a 38120 cell) and 10mm sides.
Cutted the side angles and bendt it together, drilled holes for output and switch.
Drilled holes and made threads for umbraco screws.
Finnished with white and black paint (same as the bike)
The box is mounted with the 4 umbracos for bottleholders (box is unshakable)
Box is made watertight with Simons industrial siliconeglue.
Cables goes out of a connection with a flexitube.

Torque arm
5mm iron metal (custom made offcourse )

I will add information and pictures/videos under the whole project, i just wanted to start sharing now
Please tell me what you think of my project

Project cost (so far)
Bike - 831$ (picked up at store)
Ebike Kit - 310$ (including express shipping from China to Norway)
Aluminium - 60$ (picked up at store)
Batteries - 341$ (including fedex international from China)
Wireless speedometer - 33$ (picked up at store)
GT Analyzer 130A - 34$ (including standard shipping from China)
BMS - 98$ (including express shipping from China)
DCDC converter - 11$ (including standard shipping from China)
Shrinktubes - 10$ (picked up at store)
Other devices like switches, connectors, about 50$.

Total cost - 1778,- US Dollars or 10668,- Norwegian kroner

Sirhaxalot

[youtube]2sgJTPV3eMU[/youtube]
[youtube]gsKzuyp_k5E[/youtube]





THE BUILD PROCESS

LifePO4 38120 cells

3DPT 30A RELAY

Relay configuration

 

[pwbset]

Oh if only we could power our ebikes with beer.

 

[sirhaxalot]

Haha, yes i agree

 

[neptronix]

Nice setup so far !

 

[cal3thousand]

Oh if only we could power our ebikes with beer.

You can. But it's not that fun.

Step 1) Drink plenty of beer
Step 2) Pedal your ass off to burn beer Calories
Step 3) Try not to puke or get a BUI



EDIT: Forgot to compliment the OP on such a sweet setup!.. Giving me ideas

 

[sirhaxalot]

Thank you

 

[bobale]

Can you post more details about that case for the batteries? I really like it, and would like to know more about how you've bilt it.

 

[sirhaxalot]

Can you post more details about that case for the batteries? I really like it, and would like to know more about how you've bilt it.

Yes sir, i have added some more information, please just ask questions if you want.

 

[Animalector]

First Question.. how did you 'mod' the conhismotor controller for 30A?

Second Question.. have you tested the Delta/WYE? I am interested if this is practical/realistic because currently I am topping out cruising speed at 48 - 50km/h and would like to be able to sneak up into the 60km/h zone to keep with traffic..

Cheers.
Andy

 

[Teh Stork]

Nice build I have exactly the same battery box configuration - only with MDF instead of aluminium. Dahls, you're from Trondheim?

Looking forward to seeing how your switch turns out Been tinkering with a microprosessor controlled one myself.

 

[sirhaxalot]

First Question.. how did you 'mod' the conhismotor controller for 30A?

Second Question.. have you tested the Delta/WYE? I am interested if this is practical/realistic because currently I am topping out cruising speed at 48 - 50km/h and would like to be able to sneak up into the 60km/h zone to keep with traffic..

Cheers.
Andy

1. The controller is modded by Conhismotor
2. Yes Delta/wye will increase top speed, but it will decrease torque, so you will need to have a relay that switches when you are around 50km/h,
either via a speed sensor circuit or a manual switch as my mod will be.
You will also need some more amps, so a modded controller is recommended.

I have already ordered a 72 volt controller for more efficiency and torque in Delta mode.
I will write review on both controllers in both speed configurations.

 

[sirhaxalot]

Nice build I have exactly the same battery box configuration - only with MDF instead of aluminium. Dahls, you're from Trondheim?

Looking forward to seeing how your switch turns out Been tinkering with a microprosessor controlled one myself.

Hey Teh Stork, i am from Levanger 80km away from Trondheim. Are you Norwegian?

 

[Teh Stork]

Nice build I have exactly the same battery box configuration - only with MDF instead of aluminium. Dahls, you're from Trondheim?

Looking forward to seeing how your switch turns out Been tinkering with a microprosessor controlled one myself.

Hey Teh Stork, i am from Levanger 80km away from Trondheim. Are you Norwegian?

Norsk ja, morsomt å se flere norske her inne Bor like utenfor Trondheim selv

 

[sirhaxalot]

Nice build I have exactly the same battery box configuration - only with MDF instead of aluminium. Dahls, you're from Trondheim?

Looking forward to seeing how your switch turns out Been tinkering with a microprosessor controlled one myself.

Hey Teh Stork, i am from Levanger 80km away from Trondheim. Are you Norwegian?

Norsk ja, morsomt å se flere norske her inne Bor like utenfor Trondheim selv

Haha, ja det var morsomt, sikkert ikke mange nordmenn her.

 

[sirhaxalot]

Engine will arrive on Wednesday 16/05 , i will do the modifications to the engine for delta/wye immediately, but will not bench test before i get the controller that will handle the amp increase. So i am getting excited about getting this thing together.

 

[sirhaxalot]

Motor arrived today, checked it for errors and then painted it black. I am pretty happy so far, next will be batteries, they are on the way. i am starting to feeling the need of trying this thing soon and added some more photos of the bike.

 

[boppinbob]

Where the hell are these people getting their mad metal working skills. I'm jealous

 

[sirhaxalot]

Where the hell are these people getting their mad metal working skills. I'm jealous

The tools are half the job, the rest is time itself - boppinbob
and patience patience patience

 

[sirhaxalot]

Added a little teaser, motor running with only 10 amps and a crappy lithium ion pack i put together just while i wait on the headway cells.

[youtube]gsKzuyp_k5E[/youtube]

 

[Teh Stork]

Nice work, looks to be in perfect true too Spent several hours trying myself in the arts of truing yesterday. My crystalyte rim started out crap, but is next to perfect now - steep learning curve

 

[sirhaxalot]

Batteries has arrived and i have soldered and used shrinktubes over the cells so they can handle more stress and beating, used flexible 6mm2 silicone cable and tomorrow i will be fixing the batteries in the box, more pictures will come, i hope i will be making some commuting videos and experience faults and errors on the way. mods and stuff will come.

The box i made is 84mm wide inside, i was pretty lucky when i used shrinktubes on the batteries, they became in pair 84mm wide
they are originally 38mm pr cell, so the crimp is 2mm thick, this will make them very robust.

 

[sirhaxalot]

I have tested the bike around the block, tomorrow will be first day of commuting to work, cant wait

PS!! The sound of the video is totally screwd, suggest to turn down volume of your speakers, it is my phones fault!

[youtube]BcJWtmS-98Q[/youtube]

 

[sirhaxalot]

 

[sirhaxalot]

Got my stickers today "NB ELECTRONICS" stands for Nonstad & Bentzen Electronics, me and a colleague of mine that have also built a ev.

 

[sirhaxalot]

Today i have added a 10K pot meter in series with output signal of hall-sensor in the thumb throttle, i adjusted the pot meter until the bike peaks at 300 watts and 6 kmt, i short the pot meter with a 1mm pin trough a 1mm hole in the side cover of the thumb throttle to achieve original speed.
Works great if you get stopped and they want to check legal speeds on dyno.