Thursday, February 1, 2018

Motorized Retro Direct Drivde

Two motors and Two gear speed gear box?

A heavy human powered vehicle (HPV) that can drive 450lbs total combined weight up the steep hills in Vancouver will need at least two gears to climb the steep hills with a legal wattage. Read more: cycle tractor.

With 7500 rpm output for maximum momentum efficiency using a high voltage motor, you will need a lot more gear reduction (like 13:1 total) to keep it down to about 11-13mph [17-21kmh] on a 9% to 10% grade but even that would be quite a fast gear with Canadian legal power.

So two motors would be needed. Making the vehicle illegal only when you need to turn on the second motor. But it will still not be able to drive faster than the speed limit if the gears are low enough. About 16mph [26kmh] on flat land.

A retro-direct drive is a fast (high gear) in the forward direction and a slow (low gear) in the reverse.

Making a switch to reverse the motor: (see the middle of page 5): Epicyclic retro-direct 2 speed transmission.

There’s a problem with the design of planetary gears – there is inherent backlash and play between the gears. There can be problems with binding or jamming. It would be better if the prototype was made without planetary gears.

A hypocycloid gear could be a better way of gearing down but without tight fitting gears you can have the same problem. A harmonic drive would be much better if you could design one to do this retro-direct switching.

The ring gear is attached to the output
 shaft and the planet gears are stationary 
on a plate with a one-way bearing
 in the opposite direction.

more here 

Friday, January 12, 2018

Motors for Pedicab Rickshaws

Front seated rickshaw pedicabs are so much easier to motorize than the kind with the seats in the rear. Applying the motor to the single rear drive wheel is like motorizing a bicycle.

There are advantages to using a single gear reduction with a belt drive, that will move only 10 to 13mph on your worst hills. Even with two motors operating at once you will never be able to drive faster than the legal speed limit for such a vehicle. A high voltage, low amp controller with high RPM gear reduction is much easier on the motor by wasting less energy as heat.

You will have plenty of torque thrust starting across busy intersections. And you don't need motors running on vertualy flat land. Muscle power should be used for easy terrain.

But with 800lbs you will need some fabulous double pad hydraulic disc brakes. Or you could find out the hard way what happens.

If you want to go slow without a gear reduction and pull heavy loads get the CRYASTLYTE X5306 and it will move along at 2-3 mph and pulls like a mule. But gear reductions are more efficient, and easier to fit into a legal frame work if the idiot law makers would understand that gear reductions can be made to stay under the speed limit with out electronics. Which would result in the impossibility of some wise guy making a hot rod out the vehicle.

Due to people ignoring the e-bike laws and the complete lack of understanding about how powered bikes should be built electric-assist pedicabs were banned in New York City in January 2008, along with all other forms of electric vehicles; the city council decided to allow pedicabs propelled only by muscle power. The city of Toronto Canada decided not to issue permits to electric-assist pedicabs.

If you want to use as much power as it takes to move 800lbs up a steep hill in the U.S. you must get a computer-simulation done to prove the safety of your vehicle. And that costs many thousands of dollars.

So it is not likely that rickshaws will ever become popular in the land of milk and honey. Until there is no more petroleum left.

Power at the wheel needs to be 1497W to go up a 9% grade at 14mph carrying 600lbs, 1294W to go 12mph. When we have only 400lbs, we are at 859W for 12mph, and 994W for 14mph. This all assumes you are already traveling at those speeds before you hit the hill.

Had Oregon law been more like Ontario law, which states that the motor has to have continuous output power of 500W, you could get around it by having much higher peak loads for short periods. Talk to a state congressman and get them to change the law so it states "continuous output power". Giving you the room for peak bursts up hills.
To move a heavy vehicle up a steep grade slowly the motor needs a lot of copper winding to handle the energy wasted as heat. Or you can use a faster higher voltage and less amperage to achieve the same wattage at a more efficient RPM. But of course you will need a larger gear reduction. So most people end up using an over-sized motor that will waste energy and run the risk of conflict with the laws. 

Gears do not waste energy, they convert torque RPM into thrust, and increase efficiency by using more momentum

Recommended Motor for Pedicab?

Monday, August 7, 2017

Take Action NOW, Before it is too late!
If you really want to find a way to live without a car, start taking notes about what you carry, how far and how steep your hills are. You might be able to live with an electric bicycle as a second vehicle a lot easier than only a bicycle, even with a motor. I would rather pay for an electric bicycle that can handle much more total combined weight than I will ever carry, on hills that can be avoided most of the time, than to find out a few years down the road that I put too much stress on the power-system too often. Electric bicycles can be built to last twenty years or more. But most factory parts will not last even half that long.

After a few months of taking notes you could take an educated chance at living without a car for a while. I know a magazine editor that did it for a month or so. But he learned that it was impossible to maintain a American family without a car. And that their car cost them around a thousand dollars a month (over the total life span of the vehicle) in the 1990's. And that was in our SMALL town!

450Lbs total combined weight is easy to achieve. The average American weighs 200lb +100lb for the bike, leaves 150lb cargo. But most bicycles can't handle even that much extra weight. How much do you think children weigh? 350Lb total combined weight is easier to motorize.

I know people that are rich enough to own an electric bicycle and still not use it except for good weather joy riding and to run a few errands. My knees are so worn-out from arthritis that I may never be able to ride without a motor again. And I have no car, nor can I even think about paying for the maintenance and insurance of one.

If only 1% of the world's population can think "outside the box". The rest are firmly stuck within the box, so writing this blog maybe a waste of time unless someone is willing to learn to think outside of the box. You can start by not standing in straight cue lines at the stores. There is an insane psychology of how people stand in lines. I usually try to keep the lines from blocking the isle by turning it, but people get nervous and act like someone is going to steel their place in line. This insanity also shows up as 'bumper-to-bumper' driving. I don't think I can stand it much longer!!

Alt-right's hidden agenda:

Saturday, August 5, 2017

Mileage Comparison

Miles per gallon comparison of vehicles, to electric bicycles. Locally produced energy gives better mileage.

Saturday, June 17, 2017

Big Bulk Box Bike
If anyone can build these street legal they can sell a lot more of them”

This is the most heavy duty “looking” cargo bike that I have seen made in the industrialized world. Unfortunately they used two hub motors. Making this street illegal in Washington state, and a number of other places.
People are so obsessed with speed they think that even a large heavy duty cycle truck should be able to drive as fast a motorcycle. Yet they refuse to consider that there are good reasons that motorcycles have really powerful brakes and very heavy duty tires.
Not only are hub motors a waste of energy, but they use more energy than is needed to climb steep hills.
I am going to have to stop writing this blog, people just don't care. But if you want to sell these vehicles use your brain by reading these pages.

Electric Overdrive / Magnetic Gear Motors? / Fixed Gear Drives (Non-Hub Direct Rear Drives) / New Motor Technologies / Custom Belt Drive / Two speed gear boxes for bicycles

Two motors with two controllers will give you more speed with a larger use of power. But an extreme gear reduction would use less power, and just not because of the lack of speed.

Here's the simulation for dual MAC8T motors assuming equal sized wheels with identical controllers. As you can see the motors are out of the controller-limited region (after the peak inflection point of the red motor curve) and so are not bound by the controller amp rating and are running at near peak efficiency even though they are climbing a 9.5% grade. This requires about 54 battery amps which should not be difficult to achieve (you want to run a single battery - avoid the control and monitoring complications of using two).

Here's the simulation for dual MAC8T motors assuming equal sized wheels with identical controllers. As you can see the motors are out of the controller-limited region (after the peak inflection point of the red motor curve) and so are not bound by the controller amp rating and are running at near peak efficiency even though they are climbing a 9.5% grade.
This requires about 54 battery amps which should not be difficult to achieve (you want to run a single battery - avoid the control and monitoring complications of using two).

This technique is essentially a graphical analysis that gives viable results given the constraint of equal sized wheels and identical motors and controllers:

  1. Set up for one motor/controller/wheel and run the simulation
  2. Scrub the cursor back and forth, until the required load power is twice the delivered motor power (for 2 motors)

In the above example, you need 1600W to climb the grade and each motor will be loafing and supplying only 800W.

two motors are better than one

If you run equal wheels/motors/controllers, you can use simple Infineon trap controllers and will get optimum efficiency under almost all circumstances using a single throttle with no special tuning.

Recommend, would be a CA3 to drive the two controllers to get the throttle ramping, and current throttle for smooth operation + 2WD PAS and/or auto-cruise if you wish... Since the drives are the same, you can use the CA to monitor the temperature of either motor and assume the other motor is about the same temperature. This gets you automatic thermal power rollback to avoid cooking the motors if you try to overtax them.
    Remember, electric motor power specifications are in terms of 'rated power' not the actual power you run it at. So a 500W MAC can easily be run at 1500W although it will heat up and eventually overheat with this overrated operation. But legally, it's still only a '500W' motor.

Do not be confused by comments about testing the output of a bike - the traffic statutes are written to facilitate field enforcement - so many cc's or so many rated Watts - not the actual hp output of a motor which an officer could not possibly measure. He needs to be able to make a decision based only a quick look at a motorcycle model plate or wattage sticker - hence the way the statutes are defined (of course there are some really confused state statutes out there, but that's another matter...) But a label that says 500w would help.

dual controler assembly

Saturday, June 3, 2017

Free Money

If we want to deal with the big social, economic and environmental challenges that we’re facing today, we should start by fixing money.

What We Need to Do

1. Take the power to create money away from the banks, and return it to a democratic transparent and accountable process!!!

2. Create money free of debt!!

3. Put new money into the real economy rather than financial markets and property bubbles!!

Tuesday, May 2, 2017

Longest Lasting chain-oil Formula

 I have been using this mix of STP (w/zinc oxide) and a thinner “sewing machine” type of oil to thin it out a little bit. And finally I put PTFE in it. I clean my new chain with Naphtha solvent before applying this lube. And I have to heat this oil in an eye dropper bottle in hot water to get it to penetrate the chain, but it lasts about a thousand miles. A lot of people just cannot under stand chain oil. They even think that wax is a lubracant.

Tuesday, April 11, 2017

Crisis of intelligence!

Every one I know is either a 'nihilist' or a 'denialist'. 

Most people have no idea how bad life will be without gasoline. The USA will be the hardest hit, just because we are so addicted to petroleum. In other parts of the world they are gearing up to move away from fossil fuels fast.

But you can forget about large electric cars! They are going to be very expensive and inefficient because the energy mongers want your money! And when electric bikes get in the way of too many cars there will be a crackdown.

The laws will not change until we all understand the problems. This will not happen by building illegal vehicles. Manufacturers of e-bikes need to understand what it takes to build electric bicycles correctly.

This will involve a rear wheel, belt driven directly from the motor, and a crank activated power system that cannot push the vehicle faster than the law allows. Unfortunately most people want a vehicle that moves as fast as a car! That is a crisis of 'ignorance' (denial)!

There would not be a problem with e-bikes if they were geared so that they cannot be driven faster than 20 mph; regardless of the amount of power used!! All you have to do is take the maximum RPM the motor will produce, and calculate a gear ratio to keep the bike under the speed limit. This will give you much better hill climbing ability, with less power!

Or use a speed sensor to cut off the power when moving faster than the correct speed. This will allow you to travel at, or below the speed limit all day without burning out the power system. But the speed sensor can be by passed too easily on some e-bikes.

Hub motors are responsible for the power limitations of e-bikes, simply because once you have that one-to-one gear ratio of a hub-motor, the cyclist will be able to exceed the speed-limit with as little as 350 watts. And Mid-Drives are even worse!

The main high tech thing to look for is a controller that has a voltage multiplier in the slow speed output range.

Build a sexy micro car!

velomobile design from the 1940's

Monday, March 20, 2017

Strobe Lights for Velomobiles

Have you ever been almost wiped out when crossing a busy intersection? I have more than once. Now I have to buy a white strobe for the front just to get across the street! In the day light!!!

These are much smaller than I expected. The light face is only 2”x 5/8 inch for the 3 L.E.D. units. And you need 2 water proof switches (for a bicycle), one being a “momentary” contact to change the flash pattern.

9 watts (3w each bulb)

Wattage is not the only thing that will determine the
brightness. The 'super-bright' lights above have shaped
beams, so they may not be seen as easily as this one
that does not shape the beam. And at only 4 watts each
unit saves more than half the power as a 9 watt unit.
However if you can get the shaped beam into the eyes
of the car drivers, they will see you much better.
I am using these 4watt units on the side of my bicycle.

with only four watts you can use a smaller battery pack:

12V 2000mAh NiMH Battery Pack
Tenergy is the worst brand to use

Lithium Ion cells are much cheaper over a long period

For Lithium-Ion cells get an IMAX B6 old style charger.

The new ones will not charge through electric protection circuits. But if you don't have that detail just get newer one, but it still needs the ballance wires. The old one does not.

for a truck tail light with LEDs

This can be a complex project

to change modes

Chrome Glow 12V Waterproof Push-
Button On-Off Switch with 12" Leads

If you are building a pack, and you want to use a circuit board, the electronics are so small now these protection boards have balance charge circuits built in, so it would be even safer to charge. But the new I-Max B6 will not like the confusion of more circuits.
The I-Max B6 charger (old style) charges through the protections circuits, even though the instructions say that it will not; I set mine on 3 cell 3.6 volts per cell to make the cells last longer.
They should be charged to no more than 4.2v or even 4.1v or even less if possible. It has recently been proven that the longer a battery cell holds a high voltage the faster it will degenerate. So if you want a full charge of 4.2 volts, use it right a way. If you charge them to something like 5 volts each or more, you are begging for trouble!!!
3 Cells in series can be charged faster than single cells because they have more resistance that way. I set my charger to 1 amp. So a 4 cell pack could charge faster at a higher voltage. (1/3 volt each cell) if you need the charge faster try it at a higher voltage. But if using cheap Chinese cells charge them in a steel ammo box!! If they produce enough heat to feel you may have dangerous problems. If the pack does not have the wires to the balance plugs the cells will even them self's out after a while so don't worry about that.
The new battery chemistry {LiFePO4} is safer than the older 18650 Li-ion cells. But I do not know how they would charge in an I-Max B6. NiMH is much safer but much heavier. 

more info about lights