[toddshotrods]

Originally Posted by JRP3

Better than riding on the tire Neat concept, I didn't think you'd leave out the babe seating

Nope!

[Woodsmith]

Well you were at it persuading me I needed a honey seat...

[toddshotrods]

Originally Posted by Woodsmith

Well you were at it persuading me I needed a honey seat...

I am a very unbalanced individual. Three-quarters of my brain is preoccupied with design (work), the other quarter is obsessed with "honey". That's it - that's all there is...

[toddshotrods]

A new bright idea. I started thinking about the battery packs, controller, and motor as a whole - a replacement for the ICE. The thought was centered around two basic ideas: using the batteries to create the V-twin image, and making better use of the available real estate.

This allows a conventional, drive-drive motor, with the controller attached to the front of it, and V-cased batteries over that. The cylindrical cases kill the space, so I decided to try cubes, as a modern take on the old V-twin look.

With a custom controller/case, what's interesting here is the power would flow from batteries, to controller, to motor, all inside one assembly. Busbars could be used instead of cables, because of the short, dedicated, runs. The cubes would be detachable, so the batteries can be replaced and upgraded, without affecting the whole assembly. I could also have spares, and a compact charger that would let me take a couple cubes inside and charge them anywhere there's a plug.

The capacity is down a bit, from 4kwh to 3.4kwh, but I would rather leave it like that and wait for technology to provide better energy density. It's 18 miles (at 80% DOD) instead of 20 - I can live with that for a while... I could have stuffed more under the seat, but that would infringe on the whole "making better use of the available real estate" thing. As it is, I can stuff a charger, dc-dc, etc, under the main skin.

[JRP3]

Possible issue with solid buss bars in that they will transmit vibration to each terminal.

[Woodsmith]

You could use over sized cables from the sides of the pack, looping down under the front of the controller area, so they look like exhaust headers.

[toddshotrods]

Thanks for the feedback guys!

Originally Posted by JRP3

Possible issue with solid buss bars in that they will transmit vibration to each terminal.

Point taken. I have no issues with using cables, if they're better in a given circumstance. I was just noting a possibility - could be a bad one. When I finally settle, 100%, on a design and start modeling the enclosures and internal systems, I would be eternally grateful for input.

Just for clarification, I was thinking along the lines of a custom built Open Revolt type controller, where the main busbars that normally poke through the case poke up to the point where the battery cubes mount, serving as the actual contacts. Similarly, if the motor actually bolts to the controller case, the output busbars could be bolted directly to the motor terminals.

If those are stupid ideas, I can change and adapt without too much emotional damage.

Originally Posted by Woodsmith

You could use over sized cables from the sides of the pack, looping down under the front of the controller area, so they look like exhaust headers.

As noted it would be all internal, whether cables or busbars. I have this thing about making stuff so clean it looks nonfunctional... The stands that the battery box cubes are sitting on, are for the enclosed electrical connections, as much as aesthetics.

[toddshotrods]

That last CAD-Photoshop composite I did was inadvertently lost, because some dummy forgot to click save. When it asked if I wanted to save it I remember, thinking I already saved it - "no". Doh!

So I started over today, working on the concept of a complete EV drivetrain, packaged as a V-twin. I had been working mostly in Photoshop on that idea, and as soon as I got started in CAD I realized that I had been thinking in two dimensions. I totally missed the opportunity to expand laterally.

Cell count is up to 504 (252, 2pk Turnigy modules). That gives a 5.2kwh pack, and 27 miles of range at 80% DOD. It's 233 volts nominal, 1,430 amps at the 65c rating/2,860 amps at the 130c!!! The design is based on an Impulse 9, with Woody's idea of the chain running inside the DE cap (sprocket replacing the internal fan).

The drivetrain assembly is about 12" wide and even with the low clearance and ride height it has about 40-degrees of lean before the motor touches (nice place for "frame" sliders).

[MalcolmB]

Originally Posted by toddshotrods

The design is based on an Impulse 9, with Woody's idea of the chain running inside the DE cap (sprocket replacing the internal fan).

That's a neat idea. Do you plan to run a dry chain or a belt?

[toddshotrods]

Originally Posted by MalcolmB

That's a neat idea. Do you plan to run a dry chain or a belt?

Thanks Malcolm (bounce credit to Woody). I would prefer a belt in there, to not have a mess, but this thing probably needs a chain. With a 9" motor and LiCo cells, I might create more damage with broken belts than messy chain lube. It's not like I have enough self-control to not abuse it.