MattJ Posted July 17, 2016 Author Share Posted July 17, 2016 Ok, after torturing my printer for another couple of nights to do some final small modifications. I´ll probably now leave everything as it is, at least for the time being. I think it´s probably good enough now. EDIT: Files now available on Thingiverse. I had a hard time coming up with a suitable name for it, but then finally ended up calling it E14D - somehow it felt like a nice name for a fast electric vehicle http://www.thingiverse.com/thing:1677282 Link to comment Share on other sites More sharing options...
Hunka Hunka Burning Love Posted July 18, 2016 Share Posted July 18, 2016 Nice job! If you could get your hands on a horizontally orientated controller board, how difficult would it be to modify your design to incorporate two battery packs in the saddle bags while having the controller mounted on top? Do you have any issues with controller board overheating? I don't recall seeing what heatsink arrangement there is for MOSFETs. Link to comment Share on other sites More sharing options...
electric_vehicle_lover Posted July 18, 2016 Share Posted July 18, 2016 It is beautiful!!! I just don't like to see the nuts outside. I would try to make them inside on a hole. Link to comment Share on other sites More sharing options...
Lz Lee Posted July 18, 2016 Share Posted July 18, 2016 12 hours ago, MattJ said: Ok, after torturing my printer for another couple of nights to do some final small modifications. I´ll probably now leave everything as it is, at least for the time being. I think it´s probably good enough now. EDIT: Files now available on Thingiverse. I had a hard time coming up with a suitable name for it, but then finally ended up calling it E14D - somehow it felt like a nice name for a fast electric vehicle http://www.thingiverse.com/thing:1677282 Nice ! i think you can place the controller ( with horizontal programming) on the top of housing . You will put into 680wh battery packs ( 2 packs) based on 60-70kg man, about 60KM cruising distance Link to comment Share on other sites More sharing options...
MattJ Posted July 18, 2016 Author Share Posted July 18, 2016 7 hours ago, electric_vehicle_lover said: It is beautiful!!! I just don't like to see the nuts outside. I would try to make them inside on a hole. Thanks and I agree about the nuts being visible. However, that would make it more difficult to print as this one is printed upside down and I don´t like to use support structures when printing. But I need to see what I can come up with. In any case, I will probably remove the big knurled ones sooner or later and use regular nuts instead, which will be less visible. 6 hours ago, Lz Lee said: Nice ! i think you can place the controller ( with horizontal programming) on the top of housing . You will put into 680wh battery packs ( 2 packs) based on 60-70kg man, about 60KM cruising distance Placing the board horizontally would indeed solve many problems, but as far as I know, it has to be ordered that way and cannot be changed afterwards. So right now, I have to live with the one I already have. But should I ever print another one, then I would certainly try to get a board wich can be used in horizontal position. 8 hours ago, HunkaHunkaBurningLove said: Nice job! If you could get your hands on a horizontally orientated controller board, how difficult would it be to modify your design to incorporate two battery packs in the saddle bags while having the controller mounted on top? Do you have any issues with controller board overheating? I don't recall seeing what heatsink arrangement there is for MOSFETs. It wouldn´t be difficult at all as the two housings are identical. The board is mounted on a plate which slides into the slots. It could be removed in less than a minute and installed on top just as easily if it could be used that way. The controller board has a huge aluminium plate behind it. No heat issues so far and the Gotway app also shows reasonable temperatures when riding. Link to comment Share on other sites More sharing options...
Hunka Hunka Burning Love Posted July 18, 2016 Share Posted July 18, 2016 It's time to post up some videos to see it in action! Link to comment Share on other sites More sharing options...
MattJ Posted July 18, 2016 Author Share Posted July 18, 2016 1 hour ago, HunkaHunkaBurningLove said: It's time to post up some videos to see it in action! So you don´t believe it´s actually moving? Link to comment Share on other sites More sharing options...
Hunka Hunka Burning Love Posted July 18, 2016 Share Posted July 18, 2016 Video up, or it didn't happen. Tire looks too clean. No scuff marks on the shell. It's selfie stick time man. Go for it. http://www.thingiverse.com/thing:963866 No excuses now ^ Link to comment Share on other sites More sharing options...
electric_vehicle_lover Posted July 18, 2016 Share Posted July 18, 2016 I also would like to see some short videos. And please populate youtube with your videos of EUC :-) Link to comment Share on other sites More sharing options...
MattJ Posted July 18, 2016 Author Share Posted July 18, 2016 37 minutes ago, HunkaHunkaBurningLove said: Video up, or it didn't happen. Tire looks too clean. No scuff marks on the shell. It's selfie stick time man. Go for it. http://www.thingiverse.com/thing:963866 No excuses now ^ Damn, I´m so busted now 6 hours ago, electric_vehicle_lover said: It is beautiful!!! I just don't like to see the nuts outside. I would try to make them inside on a hole. Ok, I said I wouldn´t change anything anymore, but I just did one more version of the top cover with recessed nuts and more rounding on the edges. I need to see if I can get a decent print of it. If it works, then I will also need to re-do the handle, because the side profile will change slightly. Link to comment Share on other sites More sharing options...
MattJ Posted July 18, 2016 Author Share Posted July 18, 2016 An update: I just finished printing my first attempt of the cover part pictured above. It´s not an easy part to print. It turned out solid and mechanically useable, but the roundings, which had to be printed upside down look just awful as I suspected they would. All horizontal and vertical surfaces and the inside look really nice and clean. I´m having doubts whether I can get an acceptably looking print of the rounded parts. One possibility would be to cheat a bit and play around with some plastic putty to smoothen the areas which look bad and then paint the whole part, but I´m not yet sure if it´s worth the trouble. Link to comment Share on other sites More sharing options...
esaj Posted July 18, 2016 Share Posted July 18, 2016 1 hour ago, MattJ said: An update: I just finished printing my first attempt of the cover part pictured above. It´s not an easy part to print. It turned out solid and mechanically useable, but the roundings, which had to be printed upside down look just awful as I suspected they would. All horizontal and vertical surfaces and the inside look really nice and clean. I´m having doubts whether I can get an acceptably looking print of the rounded parts. One possibility would be to cheat a bit and play around with some plastic putty to smoothen the areas which look bad and then paint the whole part, but I´m not yet sure if it´s worth the trouble. Is that ABS? You could try smoothing it out with acetone (maybe rub it with a rag dipped into acetone). Link to comment Share on other sites More sharing options...
MattJ Posted July 19, 2016 Author Share Posted July 19, 2016 7 hours ago, esaj said: Is that ABS? You could try smoothing it out with acetone (maybe rub it with a rag dipped into acetone). No, it´s PLA. It would be quite difficult to get such large flat surfaces stay flat on the build platform with ABS as it tends to warp quite a bit, despite heated platform. The only way to get this one smoother would be to sand it and use some putty. I tried to print the other side (without the holes) during the night. The result was slightly better but still has the same problem. Unfortunately, the printer had run out of filament just before the part was finished and continued printing air, so that part is not useable. Maybe I´ll concentrate on riding for a while and save those kinds of projects for rainier days.... Link to comment Share on other sites More sharing options...
MattJ Posted July 19, 2016 Author Share Posted July 19, 2016 The long requested video, some footage from my today´s ride, about 7 km in varying road conditions:@HunkaHunkaBurningLove @electric_vehicle_lover Link to comment Share on other sites More sharing options...
Hunka Hunka Burning Love Posted July 19, 2016 Share Posted July 19, 2016 Sweet ride! Nice to have some backwoods areas with no traffic to cruise around in. There's so many cars and the odd police car around here it's hard to find some peaceful places to ride around. Link to comment Share on other sites More sharing options...
electric_vehicle_lover Posted July 20, 2016 Share Posted July 20, 2016 16 hours ago, MattJ said: The long requested video, some footage from my today´s ride, about 7 km in varying road conditions:@HunkaHunkaBurningLove @electric_vehicle_lover https://youtu.be/3sQ9o1g2cig Good video!! is much better to see a video -- and that makes me remember that I should buy a camera to get good videos like yours :-) Link to comment Share on other sites More sharing options...
MattJ Posted July 21, 2016 Author Share Posted July 21, 2016 I published the alternative upper section as there are probably lots of people around with much better printing skills and equipment than mine:http://www.thingiverse.com/thing:1683314 Link to comment Share on other sites More sharing options...
MattJ Posted July 22, 2016 Author Share Posted July 22, 2016 On 18.7.2016 at 7:10 AM, Lz Lee said: Nice ! i think you can place the controller ( with horizontal programming) on the top of housing . You will put into 680wh battery packs ( 2 packs) based on 60-70kg man, about 60KM cruising distance Is it possible to calibrate my controller ( type 30B4 ) to be used horizontally / flat on top? Or is it only possible by ordering a new controller? I could make the design a lot more compact if only the controller needs to be placed on top. The left and right housings could be made less wide and the top section less high while still being able to accomodate the same amount of battery capacity. That would lower the center of gravity and improve ergonomics. I almost hope it´s not possible since that would mean I´ll need to do a whole new design.. Link to comment Share on other sites More sharing options...
electric_vehicle_lover Posted July 22, 2016 Share Posted July 22, 2016 Regular 30B4 works only in vertical. You can ask to MicroWorks, before buying, for it work horizontal and they will ship it like that. Link to comment Share on other sites More sharing options...
MattJ Posted July 23, 2016 Author Share Posted July 23, 2016 15 hours ago, electric_vehicle_lover said: Regular 30B4 works only in vertical. You can ask to MicroWorks, before buying, for it work horizontal and they will ship it like that. That´s what I suspected. Still a tempting thought to do a more compact design based on a horizontal controller on top. Link to comment Share on other sites More sharing options...
MattJ Posted July 24, 2016 Author Share Posted July 24, 2016 I´ve now started to work on a more compact version based on the idea of having two 16s2p packs, one on each side and the controller flat on top. The double battery which I made with a basic 16S BMS from aliexpress works very well and is much more compact than two separate packs stacked together, so I can reduce overall width. If no battery needs to be placed on top then also the length of the design can be reduced by several centimeters. So this is now a version with 2 x 32 cells instead of 4x16. Same total capacity but much more compact design and improved ergonomics. The first two parts are already waiting to be printed when I find the time. Link to comment Share on other sites More sharing options...
MattJ Posted July 25, 2016 Author Share Posted July 25, 2016 First part printed, eight more to go. This time I ended up doing a less ambitious (read: less rounded) version of the top cover, but the nuts are recessed, tightening from below. Link to comment Share on other sites More sharing options...
MattJ Posted July 27, 2016 Author Share Posted July 27, 2016 An update regarding my printing progress. About half of the parts are done and I am really beginning to like the result, which is a lot more compact. You can see a comparison on the second picture. The new version has a handle, which is 10mm narrower, so the actual difference will be even more noticeable. Link to comment Share on other sites More sharing options...
Lz Lee Posted July 28, 2016 Share Posted July 28, 2016 11 hours ago, MattJ said: An update regarding my printing progress. About half of the parts are done and I am really beginning to like the result, which is a lot more compact. You can see a comparison on the second picture. The new version has a handle, which is 10mm narrower, so the actual difference will be even more noticeable. if put the controller on the top, i think you can get more space for battery pack. Link to comment Share on other sites More sharing options...
MattJ Posted July 28, 2016 Author Share Posted July 28, 2016 2 hours ago, Lz Lee said: if put the controller on the top, i think you can get more space for battery pack. Yes, that´s my intention. The upper space is no longer large enough for a battery pack but only for the controller. The side housings still have space for a 32 cell battery on both sides. So the maximum total battery capacity is still the same, but with much smaller outer dimensions of the EUC. Link to comment Share on other sites More sharing options...
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