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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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#498 · (Edited)
Turns out the scope system of synchronising the stators didnt work.
the left was still running 10C hotter than the right (50C / 60C)
that would definitely result in another blown stator.
So I turned to my cheapy Ebay AC clamp ammeter to measure the phase current between left and right and the right was about double 16A - 8A.

So I rigged the motor in the bike using only the left motor mount and left the case locks off so I could turn the right casing and see if I could balance out the current, had to advance the right stator about 2 degrees Bingo but they both leveled out at about 20A.
Took it for a test ride and both left and right stators were 60C even and the regen is a lot smoother now right down to 2kmh.
 

Attachments

#507 ·
Fan forced Kelly. CNCed a fan port in the base. Didnt gut the case for machining just used the vacuum and no coolant.
Goal is to cool the caps, chip and then the fets from the inside. After studying the layout of components I routed the air down past the caps to the other end then turns around and comes back past the fets and out the side holes. Have to paint the pcb with some water proof stuff.
Sure, voids warranty and bike cant really be ridden in the rain anyway but at 160v will need some serious cooling.





 
#508 ·
This should answer your question Feng.
I reconfigured the LiPo pack first to 42 series to see if the Kelly would handle it but it did the same thing it did in Winton. At 172v it makes the motor vibrate at low speed. I dont think the motor minds the voltage but the Kelly does.
So I then took 2 cells out and ran it at 40s 159v (162v full charge)
the vibration almost disappeared.
these are the free spin rpm's
133v = 4780rpm
172v = 5900rpm
159v = 5700rpm.

I cut the 32s12p pack down to 2 columns of 6p by using shorter series clamps that are only 3 cells wide.
used all of the left column (32s) and bused it down to the last 10 cells of the right column with some cable. The blue section is left unused.
Being only 6p I cant put any real load on the pack but now I can go make a new pack using a new socket design (40s 10p) .

 
#509 · (Edited)
This should answer your question Feng.
I reconfigured the LiPo pack first to 42 series to see if the Kelly would handle it but it did the same thing it did in Winton. At 172v it makes the motor vibrate at low speed. I dont think the motor minds the voltage but the Kelly does.
So I then took 2 cells out and ran it at 40s 159v (162v full charge)
the vibration almost disappeared.
these are the free spin rpm's
133v = 4780rpm
172v = 5900rpm
159v = 5700rpm.

I cut the 32s12p pack down to 2 columns of 6p by using shorter series clamps that are only 3 cells wide.
used all of the left column (32s) and bused it down to the last 10 cells of the right column with some cable. The blue section is left unused.
Being only 6p I cant put any real load on the pack but now I can go make a new pack using a new socket design (40s 10p) .


Factory settings:
96V =5500rpm



Custom Neodymium magnets
159V = 5700rpm



Custom Neodymium magnets good
Increases 160%:eek:
 
#510 · (Edited)
Hey Ripperton, it seems you are the expert for ME913 motor:)

I am building a sport motorcycle based on aprilia rs 125. Goal is topspeed of 130 km/h and range around 80km.

I would appriciate some help around battery pack (A123, 20Ah pouch cells).
What configuration will be best:

112.2V, 60Ah, 6.732kWh
85.8V, 80Ah, 6,864kWh

Thanks:)
 
#511 ·
Hey Ripperton, it seems you are the expert for ME913 motor:)
I am building a sport motorcycle based on aprilia rs 125. Goal is topspeed of 130 km/h and range around 80km.
I would appriciate some help around battery pack (A123, 20Ah pouch cells).
What configuration will be best:
112.2V, 60Ah, 6.732kWh
85.8V, 80Ah, 6,864kWh
Thanks:)

get a 144v 400A Kelly, then go 48s 2p (160v 40Ah A123 pouch) 6336kWh
Those motors dont mind higher voltage but high amps will kill the magnets.
But be sure to get the ME0913 (28 turn winding) and not the ME1012 (12 turn)
 
#519 · (Edited)
Hi Ripperton,

Once again all the info and reports on your experiments are just great to see and hear about.

This is a question about cooling the PMAC-DS, ME0913 motor if it was installed in a VW bug. If a shroud were built to make a chamber around the cooling exhaust slots of the motor and then a good sized fan pulled a "vacuum" on that chamber do you feel it would work very well or be beneficial?

Thanks
 
#520 ·
This is a question about cooling the PMAC-DS, ME0913 motor if it was installed in a VW bug. If a shroud were built to make a chamber around the cooling exhaust slots of the motor and then a good sized fan pulled a "vacuum" on that chamber do you feel it would work very well or be beneficial?
Thanks
Thanks Zak
Nope, axial air flow doesnt work.
I already tried it, It just moves heat from one coil to the other.
And def dont use a 0913 in a bug, too small.
try this, they can supply a water cooled version
http://kellycontroller.com/144v-12kw-bldc-motor-p-1072.html
 
#521 ·
Recent changes in banking laws allow banks to charge a transfer fee when sending AND recieving funds.
I recently tried to pay YGS $106 for 5 sample LiPo cells.
I had to pay $22 on this end and then HBSC Hong Kong fleeced another $25 so YGS recieved $81.
I have told YGS that I cant do business unless they can offer MasterCard or PayPal payments.

Meanwhile I have finished the new 40s 10p pack and am designing the quick release mechanism.
the bare pack weighes the same as the other 380 cell packs because of the thinner front and rear walls. This pack will allow me to increase the water cooling capacity because its is 50mm narrower I can put the radiator next to the pack in direct air flow and because I dont need fans I can replace the weight and room of the fans with another radiator.

 
#522 ·
Hey Ripperton,

I stumbled on this thread accidentally, and I've read the whole thing from the start, and your old thread over on 1000rr.net also. Very nice work, you've inspired me!

I don't want to hijack the thread, but can you tell us a bit about your CNC mill. Where did it come from, how much was it, how easy is it to use, etc?

Cheers.
 
#523 ·
#527 ·
Finaly got the YGS sample cells paid for.
5 cells $66
Fedex $40
Commonwealth Bank (Sydney) fee $22
HSBC (Hong Kong) fee $25
resend $25 via Western Union.
I had to resend the $25 that HSBC stole because YGS ended up not getting the full amount.
Western Union fee $20
total $198.

7kWh Pack is nearing completion at a projected 50kg with quick release mechanism.
Bike will be about 147kg in IOM format.


 
#536 ·
The entire power train is aluminium.
Pos terminal is 4mm, Neg terminal is 1.5mm folded over the aluminium braid and crimped.
the braid ends are 16mm dia x 1mm alloy tube crushed to crimp and 3 m4 drill holes across and sleeved with heat shrink.
the blade connection is 1.5mm aluminium with carbon grease.
The heat shrink will tell me if I have a heat problem. Theres max 240A going through each braid at full throttle.
Im looking at 12 seconds to replace the pack in race
 
#540 ·
New dual radiators go in beside the battery pack and cut the front lip off the R6 fairing to get more air to the rads.



on commuter mode motor runs at 42C.
just did 42km around the streets here averaging 40kmh.
opened up the hole in the tank cover to get the pack out.
the release handle sticks out a bit.



new swingarm makes for very narrow bike.

 
#547 ·
Ripperton,
For motor cooling have you experimented with pumping water mist into the air inlet of your motor cooling ducts?

have though about it and bought some garden spray mist nozzles but figured it would be too messy with water probably dripping into the belly pan.
Besides, properly designed fan blades on the rotor do the same thing only better.

Just recharged my pack from dead flat 138v and the v monitors sounding their alarms, some of the cells at 2.8 and some at 3.5v. Thats a big variation at BOC.
the (Batrium) charge program logged 1 hour 26 minutes at 24A and 34Ah and finished of at 168.4v and sat down to 164v with all cells dead even at TOC to within 20 milivolts!.
34Ah x 164v = 5.5kWh.
In a theoretical 7kWh pack thats 1.5kWh of unusable energy due to the
variation of cell capacity. :(
 
#549 ·
Its understandable because they are basically B grade cells plus they are old.
this is their second season now. They always had high IR's.

I just took the bike down for its official weigh in and was blown away

141kg

it just keeps getting lighter even though I just put a bigger pack in and added a radiator.
I figure the swingarm mod helped a lot.
 
#550 ·
Wow, thats such a low weight. I'm quite impressed and really jealous. I'll have an R6 with 8kWh that will be about 163kg and I thought that was good! haha

Sorry to hear about the battery cells. With so many small format cells its very hard to guarantee that they are all the same capacity and will remain that way.
 
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