17.8.12

Drivetrain Delerium

I have finally got around to replacing the drivetrain that gibbed, so I can stop constantly playing with the ebikes.ca calculator to pass time (as if I will!), now I have a functional electric scooter at last!
Changes include:

  • New motor (Align 700M 510kv) replacing a perfectly good motor I wrecked!
  • New ESC (Hobbywing 80A HV ESC OPTO)
  • Flange holding the belt onto the wheel
  • Batteries powering the servo tester.

I rode it around my local recreation ground briefly, I found it to have a lot of power (that old classic where you apply too much power and wheelie off the deck!), It handled a dirt track admirably, and it was surprisingly easy to ride once going (though it seemed to get bored with going straight and wished to turn a bit as soon as you applied miniscule control force).
The major problems are the aforementioned acceleration, the deck rattles too much and the controls are both fragile and unpredictable - the handle will need 1/4 of a turn to reach the bottom of the throttle and the handle came off at one point :(

If I were to do this again:

  1. More compact body
  2. Hub motor
  3. Integrated battery and ESC tucked away inside the frame
In short I would build something that I could just kick along whenever the police are nearby and jet off again when they aren't ;)

28.6.12

Brakes Alive!

Now that I have come home for the summer, I have been able to fit the brakes to the front of the scooter:
Complete folded scooter
Dual-Pivot caliper brakes
This 6061 aluminium bracket, made of 3mm L plate and 3mm x 12.7mm square tube, is surprisingly rigid.
The braking system worked excellently in dry conditions, much to my amazement; it fared a little worse in wet conditions, but it is like the difference between Labour and Conservative - barely there and why do we care ;)
On a poorer note, the Aeolian 4260 600kv motor burnt out in a massively frustrating last-minute calamity just before I was to ride it to my friend's house to show off!  I believe that it was caused by the timing in the ESC (set at 12 Degrees - the highest setting!), so I will probably order an inrunner to replace it (Leopard 5692, perchance?)
I decided to cut the motor up just to see what was inside it, I probably will not re-wind the motor due to the fact that the front seems to be press-fitted onto the stator and just unwinding is a flippering nightmare!
Dremel solves all...

25.5.12

Drivetrain Items Arrive!

I have finally got my equipment ready to test my scooter, but first, Grip Tape!
Warning Stripes, natch
Now we shall canter through the scooter's equipment:
8Ah * 30C = 240A max discharge
Naturally I found the largest single battery I could get my hands on, this is a 6S 8000mAh LiPo with 8wg discharge wires and 5.5mm plugs.  I ended up frying the plugs by accident when they shorted on the scooter frame; need a new plug which keeps the contacts physically apart and insulated (battery is fine though).
[UPDATE - Drilled out the fried plug and it's fine]
blurry image of the Hobbyking 150A car ESC
This is the only affordable car ESC I found which takes 6S LiPo batteries, it even has a fan.
This is my charger, the HK-8AC, charging the battery a bit
This charger makes a hurricane of noise, but it is so fantastic to use I didn't even need the manual to get started (okay I looked up a few parameters, so what?).  It came with a loose screen though but that was fixed with hot melt glue.
No heat shrink?  use hot melt glue.
LSD batteries for testing connections and stuph
Overall the test went well, the motor spun up well and no sign of overheating, although it was just a bench test.  I did manage to test it in situ despite the fact that I frazzled the battery connectors on the scooter frame (a smoke show I'll never forget!), it is worth bearing in mind that even in small quantities electricity has serious teeth - I feel lucky just to have a battery pack left!

[UPDATE 2:  I have done another test of this drivetrain:  The scooter has lots of power (not sure how much - might nab me a turnigy power meter :) ), acceleration was manageable and surprisingly the ESC brake is very effective!  Since the motor remained at reasonable temperatures throughout the tests (acceleration followed by braking down my university hall of residence), the only thing to do now is to build me a proper throttle and affix the braking hardware to the front fork.]


22.3.12

Project Flying I-Beam Part 2

This is the aluminium chassis designed in parallel to the plywood one:
This version was less bulky, probably lighter and less complicated to build, which is to say I couldn't be fucked to make all the intended dove-tail joints (bless my boring little life); additionally, my big brother (An Engineer at TRL) was concerned that the wooden design might break which is the last thing to want on a scooter that can be flummoxed by a seam in the pavement.

Specs are the same as before:

Specs:
  • Aeolian C4260 600Kv Motor
  • Turnigy Trackstar 150A Car ESC
  • 6s1p Zippy Flightmax 8000mAh 30C Flight Pack
Enough about the past, let us head forth to the present!

This boxy body is essentially what I have above, minus some details like those rakish compound angles on the lid and the box sections on the bottom (squint on the front).
Blurry as fuck image of complete scooter body when in use.

Rear wheel with HTD3 88 tooth sprocket and (absent due to shittiness) Band Brake
Fan hole with sloppily-glued pin for the (poorly executed) Band Brake
Intended Powerplant with integrated belt-tensioner
I am in the process of finalising the powerplant arrangement and braking system; I have de-rated the powertrain to around 800w for my own safety and to protect my scooter from becoming a lithium-fueled mobile hot-plate.  I also have a rudimentary setup to provide braking although this is by no means finalised:
Tektro Caliper Brakes:  These clamp over the front wheel in the usual way.
Unsuccessful attempt to make a rudimentary bracket in order to test the caliper brakes, Aluminium and braking forces, hmmm...
















Project Flying I-Beam

Most of this post can be considered Retcon, because I was too lazy to write construction logs.
Not that you should feel left out or anything, the story of this scooter, indeed the final construction, is almost insultingly simple:
This is the original plan, a 12" scooter bought for £35 on ebay, this is an unfinished Google Sketchup model as this idea was so bad I abandoned it before it could break one of my legs in some hitherto suspected accident.
<arse-kissing to prevent heated argument> If you are the seller, I am not faulting your sales conduct, it was second-to-none; it was me who should have known better than to buy bargain-basement when sending 3000 watts through one (perhaps two, if I had proven insane enough) wheel(s). </arse-kissing to prevent heated argument>

UPDATE 10/04/2012:  The 12" Scooter
This is the Scooter:
Some Modifications were made (to no avail) to correct problems of braking and handlebar height
Standard "BMX" Type bars which were too low, but could have been sorted with some welding
The Single-Pivot Caliper Brake, the only effective braking system (in a dangerous-lack-of-stopping-power sort of way)
The Rear V Brake which even after considerable tweaking failed to offer any slowing at all
This I suppose is the disadvantage of internet shopping - you have no idea what you buy until you receive it; however, all is not lost:  The frame has rusted a lot less than I thought it would, so it may be cut up for some other project at some point (welding/brazing practice at least).  As for the wheels, I may use them for a Python Recumbent or even my second electric scooter.

Just to satisfy curiosity as to what I was to arm this scooter with, here is the specs and calculations (courtesy of ebikes.ca):
N.B:  This was on level ground, 2800w was projected on a gradient of 13%.

Specs:
  • Turnigy 80-100 180Kv Motor
  • 120A Speed controller of some description
  • 2 x 6s1p Zippy Flightmax 8000mAh 30C Flight Packs
 Of course this was before I knew that A)  Aircraft ESCs do NOT monitor the current they pass and will go bang should too much pass through and B)  Li-Po batteries had a nasty habit of toasting themselves in the event of short circuits.  Watch enough videos such as this:  Overcharging LiPo Battery  and you will SHUDDER at the thought of a short circuit of one of those!

The next step I took was to abandon the 12" wheels and go for something a bit more compact:
There is no two ways about this, it's a wooden brick.
The plan at this point was to hack up an obscure model of JDBug (Stunt Series with the 140mm wheels) to obtain the folding mechanism.  I was hoping that I could haul this around as a nifty transport solution for the solitary trips I take to various british cities by train.  This version was made of Plywood all around save for the folding front end.

Specs:

  • Aeolian C4260 600Kv Motor
  • Turnigy Trackstar 150A Car ESC
  • 6s1p Zippy Flightmax 8000mAh 30C Flight Pack
At this point I scaled down my ambitions to 1500w power output since the knowledge of de-rating all components had still gone over my head.  I had also seen fit to add a 60mm fan over the motor to keep it nice and cool:
Delta Fans:  Ears not welcome within 100 yards
 I seem to have hit the limit of what one post can contain, see the next post for a parallel design in Aluminium.

First Byte

(Anyone who expresses distaste at the title for my first post can buy their weapons of punishment here)

This post is here to introduce me, natch.  I am B1t5yn8tr; machine nut, busy-handed and rule-of-3 obsessive.  This place is where I will post my machinations and other curious thoughts partly because I'd like a place to dump this stuff, but mostly in the whimsical, almost pathetic hope of them being somehow noticed by the outside world; if the second happens, I am going on record as saying this:  I will put coal dust on some corn flakes.  And eat it.

Speaking of dust, I would like to assert that about 90% of every idea that makes it here will remain just that:  dust.  Of course I will not keep you from project updates if they do become reality, to do otherwise is like showing an ankle at the Albert Hall circa 1873 as far as being a tease goes.

Finally, I should mention comments.  I have chosen to not have comments (edit:  I stopped being chicken little and enabled comments) for viewers for the reason that I am a delicate flower who needs to be wrapped in social cotton wool I would rather this blog had less clutter around it; if you feel like giving input, or indeed take issue with anything on this site, drop me an email at ssparey@googlemail.com.  People tend to think more about what they put in emails anyway so this will hopefully weed out the internet's most "successfully" bred badass-emulators (we can only hope).

Good day.