Today I was finally able to start making the battery boxes. Here are the definitive drawings of how I'll be making them. With 4 battery boxes, should all fit nicely. Just still have to see where to place the sensor plate for the display and the fuse with fuse holder. Will probably be as close as possible to the emergency switch so I can keep the cables short.
I started with the biggest box. It'll be the most difficult so I just want to get it done and over with. Here are the plates, nicely tailor-made with my table saw. Only the back plate (as it'll be in the frame) and cover are slightly bigger so I have some play. This will be evened out later on.
I glued two of the plates now, will have to wait untill this is hardened.
Tomorrow I'll continue with the other 2 plates. I just still need to make holes on one side for the cable glands.
Posted on 8 June 2013 at 11:37 pm (CET)
Category: Electric motor
Was busy making a small plate for the RPM sensor, had to remove the adaptor with sprocket from the motor for this. But I couldn't get it off, seemed to be stuck somewhere while the set screw was loose. So I went to buy a set of disk pullers to still be able to take it off. After 2 hours and 2 broken disk pullers I finally managed to take the adaptor off. But what I saw next didn't really make me happy. The axle was damaged by the set screw that's in the adaptor.
I think this happened because the set screw was tightened and after that I tightened the bolt on the sprocket. This also moved the whole adaptor and so this is the consequence. Partly my own mistake ofcourse but also the design with the set screw not working well. Wasn't my own idea anyway, I wanted to do it differently.
The adaptor itself is badly damaged as well by all the attempts to get it off with the disk pullers. Didn't mind it that much, was more important that the motor would not get damaged.
I now want to have a new adaptor made that exactly matches my own idea. It'll have a keyway so I can just place a key between the axle and adaptor. A lot better and stronger that way. The sprocket will be attached the same way though. It will also get the exact size needed so that no set screw will be necessary. The bolt on the sprocket will keep it attached on the axle.
I checked if I could repair the axle a bit and it went pretty well with a fine grinding stone and some fine grit sandpaper. It'll ofcourse never be as new anymore but I don't think I could get it any better than this.
Now I have to wait again for the new adaptor. Meanwhile I can already start on the battery boxes though. Only having some trouble with plastic welding so I'll glue the insides first and maybe after that I'll still weld the outsides.
Today I've been busy modifying the controller's enclosure a bit. First a picture of how it looked like originally.
And here what it looks like now.
On the sides I bent those outside parts inwards and fitted rivet nuts in there. In all other mounting points I also fitted rivet nuts. I think they're great, already used a lot of them too.
On the top plate I cut off the outer parts and filed them nice and straight. Also filed all of the sharp edges so they're rounded now.
Looks a bit better again and it seems smaller as well now. But what's most important is that I can let the mounts which will be attached to those points where the exhaust silencers used to be just drop down since the enclosure is exactly the same width now.
Also received some more parts today. The ABS plates to make the battery boxes, EPDM rubber to make them waterproof and a hole punch set to be able to make some rubber rings.
Just tried fitting the batteries, I have good news and bad news.
First the bad news, they don't fit the way I've drawn them.
And then the good news, they fit even better. Instead of 5 battery boxes I will only need 4 since I could still fit 1 more battery where the radiator used to be.
The battery box with just the one battery will no longer be needed which I'm very happy about. I had no idea how to place the cable glands to let the orange cables pass through. On the top and side the frame would be in the way and pointing it towards the ground didn't seem like a good idea either.
So they all fit perfectly and there's still 6 mm of space everywhere as well for the battery boxes to go around the batteries. Here are some pictures again.
The big empty space in the middle of the frame is where the charger will come and on the sides of it probably some smaller parts of the BMS, display and main fuse.
I also hung up the controller's enclosure with cable ties. I want to have mounts made for this that will come down from those 4 points where the exhaust silencers used the hang from. But I'm not sure yet how I want to have this.
That was it for today.
Some more news today. I went inside to get something and suddenly heard a van stop outside. So I went to look at the door and it was the delivery man with 2 heavy packages from Amsterdam. What could be in there?
Was a surprise since I didn't even get a message yet that they were actually sent. But the batteries are finally here. And with connection plates, bolts and Nord-lock rings included.
Just not from that official dealer where I still had to wait 8 weeks but from New Electric here in the Netherlands which did have them on stock.
Here are some more pictures.
Also measured and numbered them all. As far as I could see there are no defects. And they're all charged at the same level. There are 11 batteries at 3.286V and the other 13 at 3.287V. For now I put them back in the box again. Will first have to try and fit them in the frame and then start making the battery boxes.