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RIPPERTON Electric track bike

735K views 1K replies 105 participants last post by  Abhishek e 
#1 · (Edited)
Index:
page:
1-8 trash talkin
9 Magura throttle
11 Kelly controller
12 Life tech cells
13 Motenergys arrive
17 LiPo cells
19 Motenergy ME0913
21-24 magnets
27 first track outing
30 custom rotor
32 ramair
33-34 first round 2011 eFXC Eastern Creek racing & trophy
35 battery design
38-40 water cooling
41 air cooling controllers
42 new higher voltage LiPo pack 177v and controller probs
43 round 2 eFXC 2011 Winton
44 round 3 eFXC 2011 Wakefield
47 blown motors
48 Swingarm pivotectomy
51 fan forced air cooling for controllers
53-54 40s10p LiPo pack
55 141kg weigh in
59 charging process
60 BMS
61 Wakefield 2012 & Boost function
63 damaged LiPo's, 12v power source, weight distribution
63-64 Currie thumb throttle as regen lever
64 Revision A stators
65 YGS LiPo
65 Willowbank eFXC
66 The QuadStack begins
73-74 Electroless Nickel Plating
76-77 YGS LiPo pack 42s10p
77-78 twin Kelly controllers for 1200A
78 QuadStack outrigger bearing and stator temp monitors
79-80 testing, 12.5 second quarter 200kmh. busted synch chain
81 oil slicks, dynos & GSXR radiators.
82 The competition, Varley, quad water pumps, New YGS lipo's Wheelspin video
83-85 first round 2013 eFXC Wakefield
84 more synch chain drama and 154hp dyno run
86 battery case cooling ducts SMP test session
88 pit cooling fan and Caveman V Alien
89 chain lube guard and first crash
90 twin battery packs (quick swap) and eFXC round 2 Queensland
91 cooling fans on the LiPo pack
93 Round 3 eFXC Sydney Motorsport Park and hydraulic regen lever
95 Welded Kilovac
96 2013 Australian eFXC champion !!!!!!!!!
98 Windows 8.1, motor rebuild, Battery and motor rebuild
100 2014 eFXC QLD race report
101/102 Winton 2014 race report
103 New Kelly's
104 Wakefield 2014 race report.
106 Copper Mosfet heat sinks, Brammo
107 SMP 2014 race report.
108 cameras, photos, Kelly single box.
109 the Quadstack gets the CHOP, Mallala race report
110 Mallala, accelerometer readings, got brakes ?
111 The wrong magnets, bloody Chinese.
112 CNC cutting Neodymium magnets.
113 Round 3 eFXC SMP Sydney 2015
114 Round 4 eFXC QLD 2015 and my first LIPo fire
115 Round 5 eFXC Wakefield 2015
116 Round 6 eFXC Winton 2015
117 Round 7 eFXC SMP Sydney and rain tires
118 Round 7 New rider Brad Swallow and Mugen Shinden Go
119 Phillip Island First Club Race / Mallala round 1 eFXC.
120 battery autopsy and rebuild 42s 12p 8.4kWh pack.
124 42s12p pack track test and blown motor.
125 QLD round 2 eFXC another blown motor.
126 SMP round 3 eFXC Ripperton's first crash.
500,000 views on the 21-09-2016
 
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#83 · (Edited)
Ex-Ray goes in on the top triple but slightly below it for crash protection.
perfectly visible and on a cnc 2mm alu frame sturdy enough to push the buttons without flexing.

speed pickup on the back wheel for easy motor rpm conversion.
 

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#84 ·
You can indeed set the start point and finish of the kelly throttle input, however new Kelly's don't like pot throttles. They operate much more smoothly on Hall effect 0-5v throttles I have found..
 
#87 ·
You assume that 0-100% rotation on the pot is 0-5k....

The magura I had a while back, I tested, 0-100% twist on the grip was 0-5k. After taking it apart and testing, the last part of actual rotation on that pot didn't seem to do anything, it would just stay at 5k.

Test it with a multimeter set to ohms.
 
#88 ·
Basically, if you set the top end to 80% and the bottom to 20%, then you only need to see 1-4v from the throttle. So no you dont need full operational range with a Hall effect throttle.

Magura is POT throttle however...
 
#90 ·
Yes indeed, a very useful feature.

The Kelly throttles work well enough, but are a poor fit and shape (too short a body, and convex shape make it uncomfortable). They are nice and cheap though.

We make our own for TTX02, we may make these available to the EVMotorcycle world shortly..

Steve
 
#92 · (Edited)
Designing rear pully

Ive had 9 goes at getting the pitch of the teeth right so the belt wouldnt climb up over them. ended up being 9.94mm and with the help of parametric geometry (Autodesk Inventor) the product of that dimension is the diameter of the pully (228mm).
lining up the belt over 1:1 scale printouts.
The first go I made in wood was way off. climbed up in quarter of a turn.

3D of layered assembly. Will be made out of white Nylon 10mm.
 

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#98 ·
This project is flying together faster than some other simpler projects Ive had. Even money is coming along, I should be testing this in July.

Yes of course the ME0913 is the only motor by far that will suit this bike.
Your only a noob in so much as you havent seen the true potential of this motor even though Ive already pointed out that the cooling system is inadequate for it. I wouldnt be surprised if the fan was the same part of the 3001.
As long as this motor gets massive air it will handle what Im throwing at it.
Youve probly already figured out what controller Im using and yes it does have the potential to turn my whole workshop into a black hole if the motor is not cooled properly.
You are also still in the habit of thinking the motor is where the power comes from.
Wrong The power comes from the battery / controller
The motor is the transmission, Ive already explained this. It will turn 15% of whatever it gets into heat and spit the other 85% out at the drive wheel. All I have to do is remove that heat out of the windings and make sure the windings arnt arcing or cross firing under full voltage.

Im a Mechanical Designer NOT an engineer.
An engineer reads the spec sheet and pushes the buttons on his calculator and thats it.
A designer doesnt do math. He first evaluates the design and sees where it needs to be improved and then improves the design.
Everything has to be modified.
 
#107 · (Edited)
been doing some of the low voltage work.
Using the harnesses supplied by Kelly was half the work already done.
I have a handlebar mounted precharge switch, reverse and boost button.
The boost function supplies full 1000 amps regardless of throttle position ??? not sure how effective this will be on track but wired it up anyway, likewise the reverse function...why ??? because its there.
I have a cheapo 200v voltmeter to let me know if the battery voltage is low enough to engage to controller. Over 136v and the controller goes into fault mode.

The cap box assembly is going in under here on another sheet aly tray.
 

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#110 ·
Why put a toggle switch on the precharge resistor? Its ALWAYS supposed to be connected. If you insist on doing that, you need to have a "toggle" that will work with Pack voltage. most are rated at 12VDC, 120VAC. 120VDC will NOT work on a 120VAC rated switch, it will arc.

I don't know why people think they need the precharge on a switch. Once the caps are charged inside the kelly, there is no current flow. You could keep that bike sitting there for months and the precharge will not discharge the pack. Just wire it across and be done, its not neccessary to switch the precharge.
 
#111 ·
I'm not sure what the motion ratio is on your swingarm but it looks like if you go over a large-ish bump your suspension linkage is going to go through the controller bracket.

(First picture of post #103)

EDIT: On second inspection, I may have mistaken non-moving parts for moving parts. Ignore.
 
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