Experimental Electric Vehicles

April 5, 2010

E*Speed Update

Filed under: 1 — tonyhelms @ 9:31 pm

Mounting the motor,

In previous goals set for the E*speed the original intention was to have a motor-in-wheel, single sided swing arm. This Idea will be ventured in the future, but because of budget and time constraints I had to make the decision to make a simple swing-arm mounted motor. Hopefully for next season the motor in wheel idea will be implemented.

For now I have calculated the gear ratio to a 15 tooth front sprocket, and 45 tooth rear sprocket, but from experience calculations can only get you so far. I will be using 40 pitch roller chain to find the perfect gear ratio, and then swapping the drive train to a synchronous belt (timing belt) similar to what Buell uses on there motorcycles.

Whenever you start fabricating something on this scale, you should clean the surface of any imperfections that could result in errors. Use a grinding wheel, file, power sander to ensure the surface is flat and true.

next place the motorcycle in a level place and use a sturdy support (hydraulic jack) to hold the motor in place. Ensure the motor is exactly where you need it, make sure the sprockets will clear the wheel and arm. I have found that using leveling lasers in this situation helps quite a bit.

Once the motor is where you want it ti be, start making a pattern with cardboard. Be very accurate with this as it will be exactly what you will trace and cut out of aluminum.

Cut out your pattern, ensure it fits the motor and swing arm.

Once the motor bracket is cut out and finished, it needs to be squared to the swing arm and rear axle of the bike. This is accomplished by leveling the swing arm and using aligning lasers with 90 degree squares to line up the motor shaft with the rear axle. When the motor bracket is in the position where it aligns with everything else then tack weld 3 spots to hold it on. Re-level the swing arm and motor and ensure that everything is still where it should be, Then finish weld the motor bracket.

Once all this is completed mount the swing arm back on the motorcycle, attach the motor and wheel.

Once everything is re-attached start running power wire from the motor to the speed controller, be sure to leave plenty of slack in the wires where the arm hinges. The swing arm will be moving up and down quite a bit and could result in a wire rubbing through and shorting. The wires should be covered in loom and taped to ensure no chafing could occur.

Trim the motor cover very close to the wires, this is a place where you do not want dirt or water to build up in.

When you are all done, attach everything on or around the swing arm. Lower the motorcycle on the ground sit on it, bounce up and down and ensure that nothing is rubbing, bending or chafing, if it is then it must be re-engineered. Once it is all done it should look professional and well built, remember this is a motorcycle and your life depends on your workmanship.

I just sent the sprockets out for some minor modifications at the machine shop. When they arrive I will update with sprocket information.

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