Turnigy HXT Powered Custom Cruiser Worklog

[amberwolf]

Too bad duct tape doesn't come in assorted colors like electrical tape now does.

LIke this?
http://www.duct-tape.com/
Also found at some hardware stores in the states, at least.

 

[michaelplogue]

Lent's not be banging on duct tape too much - here in America it's considered a fasion accessory!

:wink:

 

[AussieJester]

AJ, be careful with that electrical tape. That's how many of us started, before we graduated to duct tape.

Its not electrical tape mate, its kevlar packaging tape 7 strands of it can tow your average car. I wrap 4 layers around each individual pack. There is Ductorbass tape on my bike but without enoobs input you will never know where it is (and Chad wont tell...will you MATE!) and sure as hell you will never freakin see it Johnny boy I have rolls and rolls of this Kevlar tape John, my mate always has a roll on him when he drops in, if you would like to try it ill send you a roll mate, it has veeeery small amount of stretch, jokes aside John it is VERY good tape, can pop some in air bag if you would like to try it, my treat...offer goes the 'regulars' also...

I'll give ya $50 for it then

Have you powered it up yet ? Seriously not all is lost, its a relatively easy fix. As long as your soldering on the traces is precise (ie you haven't shorted blobs across the different fet leads) If you're not up to it you can send it to me and I'll repair it and program it to a current limit that suits you. i had mine up to 125 A the other day but backed it off a bit.

Perhaps look at my L337 trace soldering again buddy, the traces are brilliant makes your effort look F.A.G.S like
which is understandable Would you be mad at me if i said it was collected today ...Thursday morning
is rubbish day buddy.

Lent's not be banging on duct tape too much - here in America it's considered a fasion accessory!

:wink:

HAHA... yes but in Australia, America is the butt of many jokes, why ...scroll up and see rodgah's ::wink:: last post

KiM

 

[John in CR]

Dang, thought I caught ya. The Kevlar tape sounds cool. I think I know the one you're talking about, though I've never seen in black. For compressing those Lipo cells, electrical tape is probably a better bet, since you can stretch it and put added compressive pressure with each wrap.

Oh and for the record, I don't use duct tape. I get an advanced bonding agent used in space travel that has a special somewhat reflective UV resistant surface on one side. As durable as it is in exterior use, I agree it's a bit unsightly, so on future builds it will be only inside the battery box. As far as I'm concerned it's tops for pack building, after surviving a direct hit from an ocean wave. It figured that the only connection I didn't tape up it the one that got seawater inside to interrupt Luke's ride temporarily.

 

[enoob]

There is Ductorbass tape on my bike but without enoobs input you will never know where it is (and Chad wont tell...will you MATE!)
KiM

I saw nothing i have to take your word for it . matter of fact im rather sure you only told me bout the ductbass tape to appease the maple syrup, back bacon, beer loving (closet ductape lover) hoser in me.

that and to see if you could talk me into using it on my build only to bust my chops later

still impressed with the relentless building you do bro . great stuff

 

[AussieJester]

Dang, thought I caught ya. The Kevlar tape sounds cool. I think I know the one you're talking about, though I've never seen in black. For compressing those Lipo cells, electrical tape is probably a better bet, since you can stretch it and put added compressive pressure with each wrap.

The kevlar tape also has some stretch mate, nowhere near as much as electrical tape and you have to pull harder to stretch it
thats what makes it so good for the lipos IMO, it stretched and then pings back to normal state unlike electrical tape has no rebound type qualities like the packing tape, the down side is its poor adhession qualities which isnt an issue until you end the tape, i put a blob of superglue on the end before sealing it down which stops it unravelling. My packs are so tightly wrapped as a result anywayz, 4 wraps of the kevlar pulled/stretched around the individual packs may have had something to do with my lipos not rupturing when they were overcharged even?

HAHA enoobs you know you wanted to duct tape your MARs onto the chopper DON'T LIE you DID admit it admit it ADMIIIIIT!!!

KiM

 

[enoob]

i was too.

Frustrated with a setback i started contemplating how it could be done , even had a plan . but luckily i passed out due to alcohol consumption and woke up smarter.

 

[Hyena]

Would you be mad at me if i said it was collected today ...Thursday morning is rubbish day buddy.

Crap

kevlar tape - I can pop some in air bag if you would like to try it, my treat...offer goes the 'regulars' also...

If you have excess and you get it for nicks I'd be keen to try it. It'll partially console me for you throwing away that controller
I was looking at it or something similar last time I was at bunnings but it was like $20 a roll so I passed!

 

[AussieJester]

Ill send some your way Mondee mate still have your address handy from the controller i forwarded
No idea what it costs mate works at the fruit and
veg markets they use it to wrap up boxes
on pallets for shipping and have boxes of the tape
i guess i would have a dozen rolls laying about
its impossible to break with only your hands.

KiM

 

[dequinox]

ROFLMAO @ Crackatinnie tribe, gold...

Good ol VB ... have had many a hangover because of it... :wink:

I wonder if 66v 10ah would be enough for me, seeing my biggest trip is under 12km...

BTW AJ thats a 15ah pack? Its freakin TINY!

Yeah tiz, here's a couple measurements and weight for you



Back soon...
KiM

Shit that's amazing... I had no idea they were that tiny. I mean I've looked at the website and all but seeing a built pack really puts it in perspective! I would love to drum up a few of those... would love to be able to do 120 miles on a charge. The risk of burning lipo and my lack of experience with lithium points me toward Lifepo4 though... one day I will have that mass of blue POWER!!! Thanks for the detail views!

 

[GGoodrum]

Kim --

Below is a shot of your three LVC/HVC/6s4p parallel adapter boards. I'm working on the Charge Controller now, and then I'll finish the Battery Medic Booster. It is going a bit slow because I'm taking pictures as I go, for the assembly and test instructions that will go with the PCB-only versions of these three units. Anyway, I hope to get yours done and shipped to you tomorrow. I take some more pics before I do.




For your current setup, you would use two of these. Once you switch to the more manly 18s setup, you'll use all three.

-- Gary

 

[AussieJester]

Shit that's amazing... I had no idea they were that tiny. I mean I've looked at the website and all but seeing a built pack really puts it in perspective! I would love to drum up a few of those... would love to be able to do 120 miles on a charge. The risk of burning lipo and my lack of experience with lithium points me toward Lifepo4 though... one day I will have that mass of blue POWER!!! Thanks for the detail views!

If you check the post above this one and below yours you will see adapter boards GGoodrum is producing, with these it makes
using lithium polymer dumby proof...hence i am using them I just checked Gary has EVERYTHING you need listed on his website
now, you want to use Lipos here's what you need to make it
safer and dead simple.

Kim --

Below is a shot of your three LVC/HVC/6s4p parallel adapter boards. I'm working on the Charge Controller now, and then I'll finish the Battery Medic Booster. It is going a bit slow because I'm taking pictures as I go, for the assembly and test instructions that will go with the PCB-only versions of these three units. Anyway, I hope to get yours done and shipped to you tomorrow. I take some more pics before I do.




For your current setup, you would use two of these. Once you switch to the more manly 18s setup, you'll use all three.

-- Gary

Freakin AWESOME Gary!!! Thankyou mate ...I just need HobbyCity to get more Turnigys packs and motors now
TMaster pmed me this morning regarding what i wanted done to an Infineon hopefully he will be able to make that happen
and i''ll have a modded infineon by someone that knows what they are doing ...unlike me haha.

I think what i will do Gary is mount the infineon externally behind the seat, perhaps paint it or have the housing anodised THEN
i can stick with the current enclosure, i didn't want to have it outside the enclosure but if i blings it up and sleeve the cables
it may look acceptable, i already have mounting holes there for additional motor, the controller can be mounted either above or
below the second motor mount, either way i can stick with current enclosure which means ALOT less work for me i can
easily fit 9 packs without the Infineon in there and make the jump to 18s setup ...that will silence the frock wearing Hyena


Thanks again Gary much appreciated

KiM

 

[recumpence]

Gary,

Hmm, 12S is not manly? Oh, bummer! I feel bad now. I thought I was "All that". Now I know that I am just a manly wannabe. :wink:

Kidding around with you, obviously. The boards look really good!

Kim, I have some goodies I can send you (well, one goodie anyway). I need your addy again so I can send you a care pack.

Matt

 

[AussieJester]

Gary,

Hmm, 12S is not manly? Oh, bummer! I feel bad now. I thought I was "All that". Now I know that I am just a manly wannabe. :wink:

Kidding around with you, obviously. The boards look really good!

Kim, I have some goodies I can send you (well, one goodie anyway). I need your addy again so I can send you a care pack.

Matt

hehee yes i'm afraid we have been left behind Matt 12s is so last week it seems LoL...I just read your seeing 400amp
out of your setup though thats just wrong Matt LoL

MORE goodies!!! I shall pm the addy Matt and i insist paying the frieght at least!
Thanks mate

I just got back from the local bike shop got the parts sorted i need for the Avid Juicy 7 Hydraulic brakes i bought off Methods!
a set of pads for one of the callipers, turns out the lil clip it was also missing isn't even needed Tim (bike shop owner
and dedicated Lycra) said he didn't even use them on his own bike. I also organised a new hose, need meter
longer than standard so he's ordered that in for me, i did have it all in the checkout on Chain Reaction but was it was $AU137 bucks
for Goodrige hose ends, Goodrige hose & Avid pads.. Tim did the righty as usually and hooked me up with pads at discount
price he should have the hose by Tuesday/Wednesday so i can takez the mechanical brakes off the crusier and fit the
Hydraulics FINALLY!!! WOOT

KiM

 

[recumpence]

Kim, that is 500 amps I am seeing.

TBH, I am a bit concerned about blowing the controllers. I have hit the amp limit cutoff a couple times and that is VERY hard on these controllers. But, I will sort everything out.

I will return your PM shortly.

Matt

 

[AussieJester]

Kim, that is 500 amps I am seeing.

My mistake...even more insane mofo haha :lol:

Gary, i meant to ask before too, how do you 'assemble' your 18s setups as in the physical layout of the packs, do you lay them
down end to end or do you have them standing upright like i did the
pack in my above post? 9 packs being an odd number and all, i was thinking laying 3 packs end to end, replicating this and having them side by side then popping another 3 end to end on the
top of these in the center of the bottom parallel packs. I can't picture a 'neat' way of doing it. Any tips would be appreciated..

KiM

 

[dequinox]

Kim --

Below is a shot of your three LVC/HVC/6s4p parallel adapter boards. I'm working on the Charge Controller now, and then I'll finish the Battery Medic Booster. It is going a bit slow because I'm taking pictures as I go, for the assembly and test instructions that will go with the PCB-only versions of these three units. Anyway, I hope to get yours done and shipped to you tomorrow. I take some more pics before I do.
For your current setup, you would use two of these. Once you switch to the more manly 18s setup, you'll use all three.

-- Gary

Gary those look great! Will these boards work for LiFePo4 Cells?

 

[recumpence]

Kim,

I beat you to the video! HA!

I am looking forward to your as well.

Matt

 

[GGoodrum]

Gary, i meant to ask before too, how do you 'assemble' your 18s setups as in the physical layout of the packs, do you lay them
down end to end or do you have them standing upright like i did the
pack in my above post? 9 packs being an odd number and all, i was thinking laying 3 packs end to end, replicating this and having them side by side then popping another 3 end to end on the
top of these in the center of the bottom parallel packs. I can't picture a 'neat' way of doing it. Any tips would be appreciated..

KiM

I'm not completely sure what you mean, but I do know the end goal is 18s3p. If all nine packs fit standing up, this is much easier to connect the balance plugs into the LVC/HVC boards, as the leads on the balance plug pigtails, as you know, are pretty short. I do orient mine end-to-end, but that is mainly for aesthetic reasons, as my packs are mounted on the bike, and are visible. What I like to do is orient the packs in an "L"-shape, and then turn them over so from the end it looks like a pentagon, with the pointy end up. I then place these "3-packs" end-to-end. Depending on the pack configuration, these three sub-packs may be configured in parallel, or in series. In the 12s3p pack below, they are in parallel, and then each 3p block is then connected in series.

View attachment 2

The 18s2p below, looks the same as the 12s3p pack, but each of the three packs in the first "L" blocks are paired in parallel with the same pack in the other L-block.



In either case, there is an empty space on the bottom of the "pentagon" where I place the LVC/HVC boards, and the main pack connections. I then shrink-wrap the whole assembly, to make it nice and tidy.

I have done an 18s3p pack, using this same sort of construction method, with three L-blocks end-to-end. In this case all three packs in each block are in parallel, just like the 12s3p pack.



Getting back to your setup, how exactly were you looking to orient the packs? How much room do you have inside the box to work with?

-- Gary

 

[GGoodrum]

Gary those look great! Will these boards work for LiFePo4 Cells?

Yes, they will, with two part changes per channel. The balance connections would be different, unless you were using JST-XH pigtails, like the 5Ah Turnigy/Zippy packs use, not something I'd recommend, though. the best way, in my opinion, would be to run 18-gauge wires between the cells and the LVC/HVC boards, and use MicroFit connectors. There is a way to have a board-mounted, right-angled MicroFit connector, and the 3.5mm mini-terminal block, at the same time. That way you could have the a cable coming from the cells plug into the board-mounted MicroFit connector, and still have balancer output pigtails, like the ones shown, for use with something like the Battery Medic booster.

As soon as I get caught up, I will go back and add a specific LiFePO4 variant, along with the 8s version, as I now also have 8-channel LVC/HVC boards.

-- Gary

 

[dequinox]

Sounds good, I will keep you in mind for when I build my Lifepo4 packs. I still want to start there, despite the drool hanging off my chin from looking at ajs pack... :lol:

I know it doesn't exactly replace the BMS system you've developed but I thought it might be ok to run Po4's on just LVC and buy a monitor for the pack to check balance.

 

[AussieJester]

HAHA yes Matt you did, and MATE what a powerhouse the trike is
[youtube]WKAMus3oSdw[/youtube]
Fantastic display of the power of the RC motored e-bike setup ain't it!!!
GWhy...no problems with startup with those RC ESC Mr Recumpence SiR
don't need no stinkin infineon and hall sensors
Hopefully on a few more days and i'll be following suit...well..minus the
doughnuts..if i have a beer or three and the lads are over a burnout isnt
out of the question though LoL

Gary, cheers for the run down on the pack construction, what i was trying to explain
(albeit badly LoL) was
an arrangement like this-->



6 packs on the bottom 3 packs on the top, the adapter boards could be placed on the top of the lower 3 packs
either side of the 3 top packs...I can fit the packs like this end to end in my enclosure, i can't fit 9 standing upright
due to the 'sloping' shape of the rear of the enclosure...

I dug the Infineon out of the workshop bin last night too, somebody hadn't been finishing their Wild Turkeys, my infineon is
now wild turkey scented hahaa...anywayz...i attacked the shunt again having been unsuccessful in removing any of the copper wire i wrapped and soldered on it previously, this time i took to it with the dremel, cutting the copper/solder down the guts and then applying some heat, the copper wire could then be pulled out few strands at a time, over 30 minutes of doing small stints then letting it cool i managed to remove all of the copper, i dunno if i have wrecked any other components applying heat, hence i did it in ~2-3 minute stints, let it cool then attacked it again...




I also removed some leads i call the 'Frock leads'...replaced the 10awg wires again and the big fat CAP on the lower left of the board (needed to remove this for dremel access) and enlarged the holes in the rubber grommets so they could be run through them. I laid a small bit of solder on the shunt this time tiz easily removed with solder sucker if i have over done it.....again?



Few pics of the traces, i doubled checked these again all seem fine

I have a question about the single white wire according to Lyens 9Fet controller post this is regenerative programming lead
enable/disable Can i just leave this 'enabled' i.e plugged in permanently as i have cut the plug and joined the wires internally so they aren't hanging out of the controller. Anywayz, i have the the USB-TTL adapter for programming the controller shall have a looksee into that today, if it works i can at least use it too sort out the hall sensors on the Turnigy when i get a spare
dunno about using this Infineon on the bike though with all the heat i have subjected the components too, see if it even works first i guess....not even sure how i will do this i have nothing to hook it too haha...

Back soonz


KiM

EDIT: Cheers Hyena i shall remove the white wire entirely from the board as it wont be needed at all...regens for sissy frock users

 

[gwhy!]

GWhy...no problems with startup with those RC ESC Mr Recumpence SiR
don't need no stinkin infineon and hall sensors
KiM

No Mate its very impressive , but to be fair it was only one standing start and that was still more like dumping the throt rather than a nice slow, controlled, predictable pulling away action like you can get with a sensored setup :wink: .

 

[AussieJester]

to be fair it was only one standing start and that was still more like dumping the throttle

Your point being? Thats how your MEANT to start, youwant slow controlled
nancy take off buy a frock motor

I think we have different issues with the RC esc GWhy, i have no problem with low speed control it works
brilliant, my only problem is immediate startup when the motor clunks and syncs, i have had to
baby it as giving it even slight bit of juice produced gears slipping in the Sturmey Archer, if i can
give it a lil more beef off the start it wont be a problem, once I have motor sync i can power around at
walking pace or slower no problem, I have perfect control of throttle. Wasn't like that initially was nothing short of shocking, once
Mr Fechter told me what& where to put additional the resistors and what caps to replace OH and the current limiting was turned
off it was 100% improvement range of throttle motion was doubled its less sensitive and there was no surging.... If it wasn't for the pesky 48v limit on the RC controllers i honestly wouldnt
be bothering with sensored setup at all but yes, ol' Hyena needs to be 'schooled' for his insolence
so 66v tiz ASAP.

KiM

 

[John in CR]

Back to the big talk knocking frock motors I see. That's ok, the best lessons are taught the hard way. When can I expect my advanced notice? Warning, I repaired both of my Methods controllers, and I have a bike nearly ready for that 40hp+. Hopefully even Luke will be playing catch up in the near future. hehehe.