[RIPPERTON]

This hack was my first ever Evert. Started off costing me nothing and steadily got expensive.


It started off with a Unite 24v 200W brushed DC running an on/off switch, no controller and some DeWalt solderless packs.









Air Scoop

[RIPPERTON]

Then it got LiPo's





And started blowing up

[RIPPERTON]

So I got a new bigger motor
36v 300W



And of course a bigger battery pack, $550 worth of NanoTechs 20s 2p 84v 10ah



An of course couldnt run all that grunt through a switch so got a Kelly

[RIPPERTON]

Only problem now is the weak spot is now the brushes again.
I first got this latest build finished at 10pm at night after work and went around the block in the dark. Kelly's come form the factory set at 100% output and I was hearing a strange sizzling noise at anything close to half throttle, sounded like sausages but I looked down and the brushes were glowing in the dark. !!
Ive figured the brushes are too small and they are wearing out at a very fast rate so I want to make a new brush holder with bigger brushes.

The originals are 5mm x 5.4mm but the com will allow a 10mm wide brush.
The original brushes will contact 2 com segments at once but what Im trying to figure out is can I use a thicker brush that will contact 3 segments at once ???

[major]

Originally Posted by RIPPERTON

Only problem now is the weak spot is now the brushes again.
The originals are 5mm x 5.4mm but the com will allow a 10mm wide brush.

Wider in that dimension will help a lot.

The original brushes will contact 2 com segments at once but what Im trying to figure out is can I use a thicker brush that will contact 3 segments at once ???

Thicker in this direction can have adverse affect and could make it worse. Ideally the brush would be thin. Some thickness is needed obviously. But as you expand the thickness you start commutating coils under the influence of magnet flux causing more arcing and also circulating currents on the face of the brush.

Maybe you need a bigger (or better) motor

[RIPPERTON]

Originally Posted by major

Wider in that dimension will help a lot.
Thicker in this direction can have adverse affect and could make it worse. Ideally the brush would be thin. Some thickness is needed obviously. But as you expand the thickness you start commutating coils under the influence of magnet flux causing more arcing and also circulating currents on the face of the brush.
Maybe you need a bigger (or better) motor

I thought so
yeah I could just go to a Motenergy but I want to first exhaust all my creative redesigning possibilities.
Motenergy is a lot heavier too.

[RIPPERTON]

with a 3 teeth pitch, 2 coils spans (white) the same width as the magnet.
3 coils are in green





brush timing

[Ziggythewiz]

The initial build looks a lot like one I was working on. What was the performance like?

[RIPPERTON]

Originally Posted by Ziggythewiz

The initial build looks a lot like one I was working on. What was the performance like?

With the A123's (Ebay) and 200w it would get 43kmh with its 5 speed cluster.
Once did 27km on a charge but it took a few years to weed out all the dud b grade cells.
Some cells would crash every single charge and cut it short. I would charge each pack individually with a 12v lithium charger.

[RIPPERTON]

just bought 8 of these for $34
6mm thick 11mm wide and 30mm long
should be able to linish them down.
have designed a new holder out of acetal
pics later