New member, new project

Submitted by PaulWay on Wed, 03/02/2010 - 06:49

I've recently joined the Canberra EV group because I want to build an electric motorcycle. I'm aiming for something in about the same power range as my current Suzuki G500, although the torque curve differences between petrol and electric motors makes comparing exact kilowatts difficult.

My parts list ideas so far are:

* 2x Mars 48V Brushless DC motor - 5-10kW
* 10x Thunder Sky 200Ah LiFPO4 batteries
* Alltrax AXE4844 controller
* TBS Electronics E-Xpert Pro HV battery gauge

things I know less about but know I want:

* Battery management system
* Charger
* Continuously variable transmission
* Fuses, cutouts, cable, etc.

I hope to keep updating this regularly with my progress. My main aim by the end of this month is to put together a budget for the whole project and start buying parts.

Have fun,

Paul

Comments

brushless motor/brushed controller

by Anonymous - 18/03/2010 - 01:23
That alltrax is a brushed motor controller and won't work with the BLDC motors. You're going to need to use either a sevcon powerpak or a kelly BLDC controller. Also, those 200Ah batteries are going to be huge, and very hard to fit, maybe consider 2x each of the 100Ah batteries if anything, allows you more reasonable configurations inside the chassis

Change of motor and controller

by PaulWay - 17/04/2010 - 21:52
I've gone with a Kelly controller and an EnerTrac hub motor as well as changes to the batteries - see this update: Update 1 - Batteries I regret this post now - wonder if I can edit it. Have fun, Paul
-- Open the box. Tinker with stuff. You can make it better.

I have the TBS Pro gauge in

by Anonymous - 04/02/2010 - 11:01
I have the TBS Pro gauge in my car and I am happy with it. You will want to have the BMS devices that sit across each cell. I have been happy with the ones that Rod Dilkes (EV Works-WA) makes and sells. I can comment further on what these do if you need it. You will want a charger that cuts out at the right voltage for your 10 cells. Rod does not recommend charging quite to the max. that Thundersky recommend but you do need to go high enough to allow the BMS devices to start bypassing a few cells to do some equalising at the end of each charging cycle. You also want to work out how use the BMS feature that warns you if one cell is below 2.5V even if the others are happy. Otherwise you could kill that cell. I have just the audible alarm of the BMS control box but you will need a light or something else on a bike. I will be happy to discuss any general issues and sources of little bits and pieces. Perhaps the easiest if for me to show you things I did on the car and you can decide if you need similar things for the bike. Peter C.

Battery management systems

by PaulWay - 04/02/2010 - 17:33
Hi Peter, Thanks for that. The instruments on the bike are going to be the big question. I'm a big lights and meters fan - I love seeing what's going on, especially with electronic equipment. So things like battery warnings and other readouts are topics for me to explore. As you say, it needs to be a flashing light rather than a beeper. Hope to see you and your car at a meeting soon, Paul
-- Open the box. Tinker with stuff. You can make it better.

Thoughts for my next bike

by Anonymous - 04/02/2010 - 17:16
Mars double stack these are available now $550.00-should be happy for 20kw with caution 600a 120v brushless kelly controller -with regen about 1200.00 cycle analyst- canadian this is the best to use shows voltages, power in and out total used, speedo and much more $250.00 wouldnt use any less than 72v worth of cells dependant on the bike mine has 24 60ah ts cells @ 80v really try to fit as many as you can with the bike you get $2500 Using Rods bms but mounted externally from batteries a bit messy but allows you to see what the batteries are doing the magura throttles are fine you could use the original and a pot but you may find this more expensive kelly would sell similar $30.00 have not found a suitable small dc converter the controller can be set up like this ,turn the bike on at the key latches the main contactor- pushing the start button latches a relay to turn the controller on , kill switch or key turns it off mine is wired this way makes sense This should put a smile on anyones face that rides it !! Geoff OToole GTTooling