tag:blogger.com,1999:blog-6231841547435511043.post8564466789671811786..comments2023-06-13T01:05:30.996-07:00Comments on The Electricle™ : Bicycle Electric-Motor-Assist Project: Motor Tests, Mounted on CrazyBike v2.0M.E.http://www.blogger.com/profile/15375034485988839284noreply@blogger.comBlogger4125tag:blogger.com,1999:blog-6231841547435511043.post-10705515533737694662011-05-07T23:26:12.519-07:002011-05-07T23:26:12.519-07:00Well, the first issue is that you're going to ...Well, the first issue is that you're going to need a lot more reduction than what you have, because taht motor is designed to run really fast and be geared down a lot to have the power it does. If you look thru my treadmill motor experiment, you'll find I had to use a two stage reduction before going to the pedal crank, with a total minimum reduction of at least 30:1.<br /><br />I did it by using the original treadmill poly-v belt and pulleys, then a jackshaft with #25 (scooter) chain and chainrings, to a final jackshaft that mixed both pedal and motor output into the actual rear wheel drivetrain (complete drivetrain from bike including shifters).<br /><br />It can be done less complexly, but I just used what I had, isntead of buying new stuff for it. You could go all new parts and work out a reduction for it that would be sufficient in a single stage, probably, if you have enough room for the very large pulley or chainring you'd need on the drivetrain input and can fit a very tiny pulley or chainring on the motor. <br /><br /><br />The next stuff assumes your motor is a brushed DC permanent magnet motor. If it is a brushless motor, then only some of it applies. If it is a brushed universal motor without magnets, then it also all applies. <br /><br />What is almost certainly happening to your motor is that there is too much load on the motor, so it cannot reach a high enough speed to have enough back EMF (BEMF) to keep current draw low enough to survive. So the current is so high that it is overheating the motor, causing the windings to smoke (which will eventually burn them out or short them). <br /><br />Also, these motors are meant to be fan-cooled, by a fan mounted on the shaft itself, which at low speeds does not move enough air. I replaced my motor's fan with one from an alternator, which moves a lot more air than the original, but still only does any real cooling at high motor speeds. <br /><br />Regarding Amps and current limits: Your 12V batteries might be marked as 10Ah, but that only means their capacity is 10A for one hour, in theory (really much much less than that), but they are by no means limited to 10A output. They can easily produce over a hundred amps for short bursts, and dozens of amps for a short time before they are themselves damaged in turn. <br /><br />If you had a controller to run the motor, you could both limit the current to it and control the voltage to it so it is not being hit so hard at startup from a stop (right now I assume you're going direct from batteries to motor, which always gives it full power?)<br /><br />If you put bigger magnet wire in it might increase it's current capacity a little bit, but it isn't going to solve the problem. You'd have to completely rewind the motor so that it runs much slower per volt that you give it (called kV, usually, basically RPM per Volt), and when you do that the motor will now be a much lower power unit, capable of much less work.<br /><br />What I would recommend is to come over to http://endless-sphere.com/forums and create a thread for your project, with pics and descriptions of what you have and what you want to achieve, and there are a lot of us that will be able to give you input, to help you figure out the best solution.<br /><br />You can find me there as Amberwolf, including the further evolution of my various projects (which I have been posting there rather than here due to lack of time, mostly).M.E.https://www.blogger.com/profile/15375034485988839284noreply@blogger.comtag:blogger.com,1999:blog-6231841547435511043.post-34291864435754377442011-05-07T22:42:18.785-07:002011-05-07T22:42:18.785-07:00I've mounted a 130V 18amp treadmill motor onto...I've mounted a 130V 18amp treadmill motor onto my HP Velotechnik Spirit Recumbent bike. I've removed the pedal sproket and mounted it onto my treadmill motor. I rerouted the chain creating a new connection between the motor and the rear wheel. I mounted the batteries on the rear rack in a weather proof lunch box and wired an on/off switch to the handle bar. I wired four 12volt batteries with 10amps in series creating 48volts, but the motor is burning out. I've isolated the burnout to the magnet wires that connect the two positive and negative magnets to the red and black 16 gauge wire. I'm thinking if I increase the magnet wire to 16gauge and solder it to the 16gauge red and black positive and negative wires I might be able to operate off of 48volts. Do you have any other suggestions?Jasonhttps://www.blogger.com/profile/18059216048872376792noreply@blogger.comtag:blogger.com,1999:blog-6231841547435511043.post-690663480469490652011-04-19T01:36:27.827-07:002011-04-19T01:36:27.827-07:00Jason said..."What are the two blue wires on ...Jason said..."What are the two blue wires on the treadmill motor used for?"<br /><br />They are for a thermal cutoff sensor in the treadmill, though I wasn't really planning to use them on the bike, because I'd've had to build a reader circuit for it to then cutoff the controller when it got too hot, which I would not expect to happen as I was not going to run it anywhere near it's limits. <br /><br />I actualy ended up using a powerchair motor instead, though someday I want to go back and try this treadmill motor and another one I have, just to see if the whole idea would work on the road, since it did on the "bench". <br /><br />The powerchair motor was so torquey that I could and did destroy chainrings and chains whenever misalignment occured, which due to frame twisting due to some poor design choices happened often. <br /><br />I ended up nowadays with a hubmotor in the front wheel, though I havea new bike in progress that will use a motor (not sure which one yet) to drive thru the chain to the rear wheel, with the pedals, as this version would have.<br /><br />More info on the two running bikes I have now, plus one in progress, is over here on the Endless Sphere ebike forums (where most of my new information is at). You will have to copy and paste each half of the two-line URL into the browser's URL bar, because blogger won't work properly with links in the comments like this now:<br /><br />http://www.endless-sphere.com/forums<br />/viewtopic.php?f=2&t=15570&start=0<br /><br />http://www.endless-sphere.com/forums<br />/viewtopic.php?f=2&t=12500&start=0<br /><br />http://endless-sphere.com/forums<br />/viewtopic.php?f=3&t=16920&start=0M.E.https://www.blogger.com/profile/15375034485988839284noreply@blogger.comtag:blogger.com,1999:blog-6231841547435511043.post-20284572717209104092011-04-18T03:28:24.276-07:002011-04-18T03:28:24.276-07:00What are the two blue wires on the treadmill motor...What are the two blue wires on the treadmill motor used for?Jasonhttps://www.blogger.com/profile/18059216048872376792noreply@blogger.com