My first E Bike project.

Discussion in 'Electric Bicycles' started by schulze 123, Jul 24, 2011.

  1. schulze 123

    schulze 123 Member

    Hi Troops,
    After building two internal combustion powered bicycles I decided to undertake an 'E bike' project for operation in noise sensitive locations such as the beach front on a summers evening. The base bike for this project was a Repco Tungsten which was bought from the local porn broker for $85.00. The alloy frame and wheels are the only thing that I will keep, the rest will be upgraded as the project moves along. The planned outcome of this project is a bike that will have a peddle assisted range of 30km and an on the flat top speed of around 38kph, anything more than this on both parameters will be a bonus.
    I don't expect this to be a lightening build but I will post info and images of the progress as the budget and time permits. All of the suspension and brake upgrades have been ordered and should start to arrive in the next few days.

    Let the journey begin.

    Cheers BJ
     

    Attached Files:


  2. wheelbender6

    wheelbender6 Well-Known Member

    Are you planning on a hub motor or building your own drive train?
     
  3. schulze 123

    schulze 123 Member

    Hi Wheelbender6,
    I should have stated the type of drive (oops), it will be a chain drive via the front chainring so that I will have seven speed gearing via the rear cluster. A Nuvici rear hub would be better but the budget won't stretch that far at the moment.

    Cheers BJ
     
  4. Neon

    Neon Member

    Are you planning to have a freewheel on the front chainring as well?
     
  5. schulze 123

    schulze 123 Member

    Hi Neon,
    Yes, I will have a freewheel on the front chainring and also on the sprocket from the motor so that when the motor is not in use it won't be driven by the pedals.
    Quite a bit of the ordered goodies turned up today and I have begun the fit out, so I will post some images of the progress tomorrow.

    Cheers BJ
     
  6. schulze 123

    schulze 123 Member

    Hi Troops,
    As stated in the previous post some of my goodies had arrived and I've been busy fitting them to the frame. The first shot is of the pile of removed items and the rest are of the new items fitted. The new forks and drive system have yet to arrive but this will allow me to carry out some of the other work that is needed without the distraction of more 'Shiney' items.
    A bit about the drive unit, the motor will be a large 'Outrunner' style (6500 watts Max. output) connected to a 4:1 tooth belt reduction system with a slipper clutch to protect from shock loads. From there we go to 2:1 chain reduction with a free wheel (to isolate the motor from the drive train when not in use) this is connected to a modified Sick Bike Parts jack shaft kit to the chainring. Power will be in the form of a 10s2p LiPo pack with a capacity of 16Ah. This all sounds a bit complicated but when it all becomes reality you will see that it is quite the opposite. I will more than likely make a cardboard mock up of the installation to show the layout and this will also assist in making sure it all fits before getting the 'Man with Mill' too excited.

    If anyone has any comments or questions, please feel free to do so.

    Cheers BJ
     

    Attached Files:

  7. Neon

    Neon Member

    You're not messing around as far as power goes. 8hp max is a lot of power. You certainly wouldn't need to pedal at all. Doesn't sound complicated to me at all. Any plans for a controller or does the motor have one already in it? Please keep posting progress as this is shaping up to be one beast of a machine. Actually you're making me drool.
     
  8. schulze 123

    schulze 123 Member

    Hi Neon,
    My plan here is not to use the motors maximum power but more so it's torque. The gearing I have chosen is quite low so that at wide open throttle the speed of the front chainring will be approx 125rpm and at cruze throttle about 70-80rpm. This speed I can easily pedal at and use the rear cluster gears to alter the road speed this also keeps the motor out of the high current draw range that occurs above 2/3 throttle.
    The ESC I have for this project is a Castle Creations Ice 160HV.

    Cheers BJ
     
  9. Neon

    Neon Member

    You could also incorporate a pedal sensor as well. If you hadn't already planned to do so. But at last someone is finally building an e-bike right. You may not be going to use the motors full power, but the option is there if you ever decide to use it.
     
  10. schulze 123

    schulze 123 Member

    Hi Neon,
    Thanks for the suggestion of a pedal sensor as I hadn't thought of that. I will have to check and see if there would be any ill effects on my particular ESC by using this item.

    Cheers BJ
     
  11. schulze 123

    schulze 123 Member

    Hi Troops,
    It has been some time since my last update due to work commitments but here is the progress to date. The new forks, gear shifter, rear deraileur and throttle assy have now been fitted. The reduction drive and jack shaft have been mocked up on the frame in preparation for having mounts drawn up. The motor has been simulated in the mock up by the green stubby holder as it was too heavy to keep in place with a couple of zip ties. For those concerned about the safety aspect of the chain drive position I plan to fabricate/mould a stylish carbon fiber cover.

    Again any thoughts or comments on the progress so far are greatly appreciated.

    Cheers BJ
     

    Attached Files:

  12. Neon

    Neon Member

    Looking good so far. That darn work thing is always getting in the way of good project progress,
     
  13. schulze 123

    schulze 123 Member

    Hi Neon,
    Yes it is a shame about work interuptions but without it the projects don't get past the pen and paper stage.

    Cheers BJ
     
  14. ZnsaneRyder

    ZnsaneRyder Member

    WOW!!!!!!

    That's an impressive setup!!!!!

    Where do you get the Electric Motor, and belt-drive reduction, that is AWESOME!!!

    I'm planning an electric build, and that motor is nice and compact (and powerful) and looks like a very good solution for E-bike! I want to get one for myself, as it's HARD to find a good ELECTRIC motor, but gas engines are a dime-a-dozen.
     
  15. schulze 123

    schulze 123 Member

    Hi ZR,
    Thanks for the comments. The motor came from Hobby King online store and the belt drive reduction system from Matt Schumaker [shumaker@owc.net]. I must say the quality of his work is first class.

    Cheers BJ
     
  16. schulze 123

    schulze 123 Member

    Hi Troops,
    I know it has been a while since I posted any progress reports but things a slowly getting back on track again. My machinist friend has finished the motor and jack shaft mounts which has allowed me to mount up the motor in its final resting place. The ESC is hooked up and the motor test run.The next step is to finish off the jack shaft assembly, fit the drive chains and tensioners. Then the first road test will be conducted and if that goes OK, then the proper drive batteries can be ordered and all the covers will be made.

    Cheers BJ

    P1010022.JPG

    P1010023.JPG
     
  17. schulze 123

    schulze 123 Member

    Hi Troops,
    The drive chains arrived and have been fitted so I thought I had better fit up some batteries, chuck on some safety gear and see what happens. Well I must say I'm suitably impressed. The torque, smoothness and awsome accelleration is everything that I hoped for. The complete lack of vibration as you power through the gears is a real joy, not to mention the 'Turbine' like howl from the motor belt drive. If the rain stops tomorrow I will post some images and take it for a bit longer run so that I can download the data from the speed controller to see what amps are being drawn and this will give me a fair indication of the expected range.

    Cheers BJ
     
  18. schulze 123

    schulze 123 Member

    Hi Guys,
    Went for a bit longer ride this morning to see how this unit tackled some of the hills in my area. I have to say now 'What Hills', this bike just launches up them. I thought that my other two fuel powered bikes performed well but on the steeper hills you still had to put a reasonable amount of pedal effort in to maintain about 38kph. Now i just have to take match the speed of the motor and take a very small amount of the load. An interesting feature of the speed control is a RPM Govenor (used on model helicopters) that when engaged will act in this application as 'Cruise Control'. Downside to this is that it lowers the efficiency of the controller.
    Now that I'm happy with the performance I will get to work on the chain guards and order the bigger drive LiPos.
    Again any comments positive or negative are all welcome and sorry that the project stalled back there for a while, but I say the journey can be just as good as the destination.

    Cheers BJ P1010036.JPG P1010034.JPG
     
  19. pedalman

    pedalman Member

    BJ I would get those chain guards on there, looks awefully close to the jewels if you know what I mean...I just almost completed my first electric build (ridable though),carry my batteries in my backpack with leads sticking out,wouldn't ya know! I use a hub motor and surprisingly they are not bad at all...(48 volt,500 Watt),very low noise,more power than I thought.
    Do those chains make any noise? I am considering a mid-drive system for a future build though.
     
  20. schulze 123

    schulze 123 Member

    Hi Pedalman,
    I am in the process of making the templates for the guards now and they will be fitted before it goes out for another run. The guards will be made from 1.5mm fibre glass sheet like used in circuit boards (minus the copper).
    With regards to chain noise, there isn't much at all. I think the use of 1/2 link chain has paid off there as it tends to flow around the sprockets better than the regular style of chain.
    Power output of this critter is peaking at 1895 watts with a top speed of 44kph and this is more than what my initial goal was. But at this level the motor temp is luke warm and so is the battery temp plus when the bigger cells arrive I will have around 45km range.

    Cheers BJ
     
Loading...