Posted on 15 September 2013 at 08:26 pm (CET)
Well that was a nice day again. The first testride is done and it was definately a success. Made a lot of pictures and filmed it. You'll have to be patient for the video though, don't think I can get it done anymore tonight.
This morning I first charged up that 2nd battery, then I connected all of the cables.
Then I setup the controller to get some more power out of it.
Attached my other new toy as well. Can already tell that this produced some very nice video.
And then it was ready to go outside for the very first time.
I was able to ride it outside right away. I did already notice that I was getting less power out of the batteries than I was hoping for. But it was still a lot of fun. The whole time I was riding with a big smile. This is what's called the 'EV grin'.
It's just a shame that it's going up/down hill here. Down hill it went pretty fast but up hill it went rather slow. Especially at the end when the batteries were pretty much empty I had some moments where it wouldn't get moving at all anymore. But I could still push it, jump on it and hit the throttle. Once it got moving I was able to get up hill again. But at the beginning when the batteries were still full it was really great. Could definately feel the power of the electric motor quite good already while not really having much power available yet. Think it was about 1kW, couldn't get more out of those starter batteries. I set the controller to 25V 120A (so 3kW) but most of the time I've seen between 30-60A. Just a small pulse of 100A in the beginning. But I definately enjoyed it. Top speed I couldn't see during this test but I think down hill it was around 30 kmh, up hill 0-15 kmh. Here are some more pictures.
Handsfree, really? Was quite interesting to keep an eye on the display.
Had to wait sometimes for the voltage of the batteries to rise back up again. It was only at 20V suddenly. After a minute or so it was back up to 24V. But the batteries were already depleting anyway.
No reverse just yet so I had to do this quite often. For the next testride I will have a reverse.
But then the batteries really were empty so I needed some help getting back up.
Unfortunately the batteries have to go back into the cars, otherwise I'd play around with it for a bit every day. But it was definately a great moment again. The next testride will be with the lithium batteries once they're attached onto the frame. Will probably still take a while though.
The video will come, just still have to edit it a bit and don't really have much time tonight. It'll probably come tomorrow.
Posted on 15 September 2013 at 12:10 am (CET)
Today I made some thicker cables so I can test with some more power tomorrow. Top speed won't really be high with just 20-24V but will probably have some more torque since I can push more amps through these cables.
Was quite some work to make them the right size and to put the cable shoes on them. But I bought an hydraulic crimping tool a while ago specifically for this so it went reasonably well.
Also put some heat shrink around the cable shoes. Might be using these cables more often when I'm bored.
Then I had a whoopsie moment. Was planning to place the sensorplate for the display on the shorter cable. But I already put both cable shoes on it so I couldn't get the cable through the sensor anymore. Since I didn't have any extra cable shoes of this size I just cut the cable, placed the sensor and soldered it. I just couldn't get the cable hot enough so it's pretty badly soldered. Only the outside really, on the inside there's no solder and the wires are just pressing against eachother. For longtime use I definately wouldn't accept this. But just for testing tomorrow it should be fine.
The 2 car batteries are also on, I'm fully charging one of them now. Tomorrow I'll just have to put a strap around them to keep them in place. The Chinese really did make a good frame. Both of the batteries just fit exactly in width. There really is no space left between them, not even 0,1 mm I think. Like they knew I was going to do this when they welded this frame.
So tomorrow will be another exciting day hopefully without problems. In any case the quad bike's ready, just still have to fully charge the 2nd battery tomorrow and connect the cables.
Posted on 14 September 2013 at 10:00 am (CET)
See here the biggest moment of the project up untill now.
Just on low power ofcourse with such small wires, 20V 50A maximum so 1kW. But I didn't really see 50A, think the wires are just too small for that and the 9Ah battery of the quad bike was empty pretty quick.
I also saw that the wheels are quite unbalanced. It could be many things though so I don't know what is causing it exactly. Could be that the rear axle is bent just a little, common problem with Chinese quad bikes. Could also be something with the bearings in the bearing house. And the wheels themselves aren't balanced yet either. It's also a straight axle and there's no weight on it, could be that it's bent a little because of that.
Tomorrow probably with some more power and hopefully a short testride.
Posted on 14 September 2013 at 12:02 am (CET)
Posted on 14 September 2013 at 12:02 am (CET)
Today I wanted to grind off a bit of those 2 mounting points so the mounts would be sitting straight. But I found out this wasn't possible since those 2 points were already even with the frame. So I found another solution, just adding a ring on the other 2 points and they sit perfectly straight now.
Another picture now everything's really attached. Eventually the aluminium enclosure will be placed around the controller. Can't leave it open like this later on with the lithium batteries, quite deadly if you'd touch the 2 terminals where the cables of the batteries are connected to.
Today I spent most of the time on the wiring to be able to start testing. Cut almost everything out of the old wire harness and tidied it up a bit with a piece of wire loom. Otherwise the wires could cause some problems if they'd hit the chain.
And something else happened today but I'll save that for tomorrow.
Posted on 13 September 2013 at 12:28 am (CET)
Very good news today, the mounts for the controller and a new plate for the RPM sensor are done and also fitted them already. Been working on it for the whole evening. I do have to grind off 2 mounting points on the frame though since the mounts are pointing inward a bit. But it's an easy fix, will do it tomorrow. Couldn't make any noise anymore here so late in the evening.
First off I removed the rear swingarm again so I could place all the new stainless steel bolts on the motor mount and to place the new plate for the RPM sensor.
Difference between my own handmade plate and the new plate for the RPM sensor. Makes mine look pretty bad.
Here are all the stainless steel bolts in the motor mount and the plate for the RPM sensor fitted.
The motor back on the rear swing arm, also with the new stainless steel bolts. Looks a lot better than with the black steel bolts which were already rusting.
The inside bolts on the adaptor for the rear sprocket are also stainless steel now. Needed fine metric for this. I think there's a lot of tension on these bolts now though, don't know if this will cause any problems. Apparently they're just a tiny bit thicker than the original bolts or something. Really needed a lot of force to fasten them. Also added the last 2 cap nuts.
And now the mounts for the controller. I'll really keep saying this, great company who made this (Geraets Metaalbewerking). It really turned out very nicely. A lot better looking than the mounts I originally wanted. And it's definately strong enough, I think it can take at least 10x the weight of the controller.
Here you can see it fitted on the quad bike with the controller already on it.
But it's all still loose, I first have to grind off a bit of the 2 front mounting points so the mounts will be sitting straight. Otherwise there will be too much tension on the mounts or the frame if I were to attach it like this. But it'll all be good, another day tomorrow. Here you can see that they're not sitting straight right now.
Here's the whole picture again. Rear end of the quad bike is pretty full now.
I also lubed the chain. And the rear swingarm's bearings didn't have much grease on them so I greased them some more. There's still something squeeking near the rear axle though when I turn the wheels, I think the bearings. But I'll be replacing them by SKF bearings anyway so I'll just leave it like this for now.
This weekend I'll definately have my first testride.