Jérôme» brushless motor

Motor bracket for Turnigy brushless motor

Jerome — Fri, 07 May 2010 01:18:49 +0000

A few days ago, I worked on the motor bracket. I also decided to make it bigger. I made is bigger because on the original bracket, I had one of the motor screws that was under a spacer. I had to remove the spacer to remove the screw. Since it is bigger, I have not problem now.

First I had to draw everything on the computer, I printed it to be sure I had the perfect fit. This is the new scooter. Since my bracket is bigger I had to drill new holes in the frame. I took the piece of paper on glued on the frame.

I wanted to be aligned so I turn on my LED flash light.

Here are the new holes.

I did the same thing here, I glued down the drawing and punch out the holes.

Those are the bottom and top of the bracket.

The only concern I have is that I am wondering if I am loosing the natual air flow of the motor by putting the motor bracket right in front of the motor vent holes. I was thinking of drilling holes but need to be sure I will not make my new bracket fragile on the edge.

On the right side of the spacer you can see washers, there are 3 washers, they help me to adjust the depth of the motor so I can aligned the belt.

I am thinking of adding this fan to cool down the motor. I bought this 7 blades turbine fan on hobbyking. It is a little bit big put should do the job. I will need to machine a bracket to hold it to the motor.

I might try other solution like a 5V PC fan.

Today I tested the motor and it works! I test the 30$ motor and at high speed, it was making this very high pitch sound. I will probably need to adjust timing and frequency directly on the brushless controller.

I am concerned about the heat generated by the motor while free running. It was running at full speed with no load for a 2 minutes and it get warm. So a fan will be needed to ensure the magnet health.

Steps before first run

Add belt tensionner
Enlarge frame
Wooden deck
Throttle wiring
Attach fan to motor

EVPlasmaman scooter

Jerome — Mon, 12 Oct 2009 19:47:56 +0000

www.youtube.com/watch?v=95DGZ94Nq9s

When I was at the Maker faire 2009, I saw this guy pass me with a electric scooter. I remember seen that scooter on the internet, his personnal website http://blog.evplasmaman.com/.

I yelled ” hey man” and he stop and we start talking. His name is Jos

He use a 3000W ( 4HP ) AXI 5345/18 GOLD LINE brushless motor.

He also use Lithium Iron phosphate (LiFePO₄) battery

The setup use 48 A123 cells. 4 cells in parallel and then 12 sets of those in series to make ~42Volts.

Is top speed is 20Mph. He also has a 3:1 planetary gear box. It turn out to be 4:1 with the ratio of the chain.

The gear box is from Matex gears.

You can find more picture here http://photo.gangus.com/v/Jos/scooter/ and on his personnal blog http://blog.evplasmaman.com/.

Motor installed

Jerome — Wed, 16 Sep 2009 15:55:21 +0000

Here is how it looks all assembled. I had no real problems when I assembled it. Everything fit perfectly!

After testing the scooter, I realise that this beefy motor bracket acts has a heat shrink! I was amazed to see that the heat was transfert to the side of the scooter, I remember the first time I touch the side, it was pretty warm. This pretty good new. I am also planning to have a fan attach to the motor to give better cooling. I am making some fan design to test it out.

The motor bracket

Jerome — Sun, 13 Sep 2009 18:16:21 +0000

To install the motor to my frame, I need a beefy bracket to hold that 2HP motor. I took a scrap piece of 2″x2″ 1/4inch aluminum plate. I made some drawing in autocad to have my template and start drilling my bracket.

A little bit of milling to make every straight.

The 4 screws are the original one that came with the motor. I really need to put some “loctite” so the motor does not fall. Vribation is your ennemy!

To prevent the pulley from moving out, I make a slot in the shaft so I could insert a “C” clip.

Next time, I will test the autocad file on cardboard before making the real part. The mounting hole are not perfectly aligned.

My first rolling test!

Jerome — Sat, 04 Jul 2009 12:48:15 +0000

I have been having real problem at home with my internet provider (Bell sympatico). There is one of there router in Toronto that has a problem with my IP. So I can not use my FTP account and I am having problem with wordpress so I can not edit or created any new post. I also realise that I can edit the time I post news. ( Like this one )

Right now, I did my first test on my Scooter! That might sound weird since there is no post about my other modifications I made. I will post them after this one.

I went today see the guys at www.vamudes.com to borrow a 60A brushless speed controller and some batteries. Vamdues is a technical group here at the University of Sherbrooke that build Unmanned Aerial Vehicle (UAV). I also went to see them because they might need a hand to build there new plane.

I have videos of my first scooter and specifications. The batteries they had was a Thunder Power RC Pro Lite MS 8000mAh 14.8V.

Specifications for Thunder Power RC TP-8000-4S4PL ProLite MS Military Spec LiPo:

Voltage: 14.8V
Cells: 4S4P
Capacity: 8000mAh
Max Continuous Discharge: 16C
Max Burst Discharge: 25C
Max Continuous Current: 128A
Max Burst Current: 200A
Weight: 633g
Dimensions: 29 x 50 x 255mm

This is a very expensive battery. It cost $329.95 USD. I will not use that in my scooter, not for 330$ and it is only 14,8V!

When it was charge the battery was at 16V and my motor can take up to 36V! We only had one single 16V battery on the scooter. The motor is so powerfull that it can make wheelies very easy! You really need to be gentle on the throttle. I would guest the speed around 20km/h. It was rainning outside so I did not test it with my GPS to see the official speed.

I will edit the video and post it online.

Inside the motor

Jerome — Fri, 03 Jul 2009 14:10:42 +0000

This is my first time playing with a brushless motor, I am very intrigue so I had to take it appart. I also needed to change the shaft, so I DO need to look inside.

Here are the pictures.

C-clip need special pliers to remove, it hold the shaft in place.

They was some spacer with different thickness. I guess when they insert the shaft in, the c-clip is not at the exact same place so this is compensate with different spacers.

The helen key on the back has to be remove.

Now you pull everything appart and get this!

There is 14 magnets and 12 coils. I also notice that all 3 wires are very long stripped wire that are twisted into coils. I have no clue is the windings is in Start or Delta. I would guest it is in Delta to provide more torque.

You are probably asking what is about having 14 magnets, 12 coils and what is Delta? Will talk about that in future post!

My electric scooter

Jerome — Thu, 25 Jun 2009 21:02:13 +0000

Here is my project about my electric scooter.

I was always interested to build a electric moving thing. In may 2009, I when in France to see familly and one of my dad and my mom best friend. His son had this electric scooter that he was not using anymore and he did not have the battery. I told him that I wanted to modify one to make it go real fast. He then gave it to me for FREE!

A big thanks to Paulo!

I will explain how I modify this scooter and all my experimentation about it.

Can’t wait to ride it!

Jerome

Motor weight

Jerome — Tue, 09 Jun 2009 20:38:49 +0000

Here is the weight between motors.

The brushless motor weight only 406grams compare to the 1Kg of the original motor.

It is hard to believe that a motor half the weight is 14 time more powerfull. Time will tell…

The specifications

Jerome — Tue, 09 Jun 2009 20:20:56 +0000

Here is my project about my electric scooter.

A big thanks to Paulo!

I will explain how I modify this scooter and all my experimentation about it.

Can’t wait to ride it!

Jerome

Here is the picture of the weight of that scooter