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Electric Motor Conversion Kit - Coggle Diagram
Electric Motor Conversion Kit
Content
Electric Motor
The electric motor is a Motenergy ME1905 from electricmotorsport.com
The motor is comprised of a couple of main parts, the stator and the rotor.
The rotor is the big block of metal covered in magnets that is at the center of the motor. These magnets are placed with alternating poles facing outward. When the stator activates, it rotates the rotor which is attached to the output shaft which drives the vehicle.
The stator consists of coils of copper wires with three phases of rotation. These phases are typically called U, V, and W. The phases repeat and these are called poles. This motor is a 10 pole design so that means the three phases repeat 10 times essentially giving the motor 30 "windings"
The motor has a continuous max power of 14.5kW with a max peak power for 2 minutes upwards of 50kW. These numbers converted to HP gives us roughly 20hp continuous with up to 70hp peak for 2 minutes.
Battery
The batteries are comprised of 1080 18650 cells.
The cells used in the battery are LG IMR18650 HE4. These cells have a capacity of 2500mAh. They have a maximum continuous discharge of 20 amps with a peak for 5 seconds of 35 amps. These cells are perfect for this project as they were cheap and very powerful. They also offer a decent capacity giving this bike a good amount of range.
These cells are arranged into two different packs that get combined together to double the capacity. Each pack is in a 20s 27p configuration giving it a total of 20s 54p. What this means is that there is 20 cells in series and 54 cells in parallel. When you connect two cells in series this doubles the capacity of them. When you put three it triples the capacity. When you put 20 cells in series with a nominal voltage of 3.7, you get a combined nominal voltage of roughly 72v. With parallel connections it increases the capacity. Since there are 54 cells in parallel and each cell has a capacity of 2.5Ah, you get a combined capacity of 135Ah. To get the capacity of the battery in kWh you multiply the max voltage of 84v with the max capacity if 135ah and you get 11.34kWh.
Motor Controller
The controller is a Kelly KLS72501-8080IPS
This type of controller is called a sinusoidal motor controller. This is due to the nature of the output voltage being in a sin wave like pattern. The controller outputs these voltages to the three phases of the motor. Since each phase is getting a sin wave of voltage, the motor controller offsets each phase by 1/3 of a sin wave to make it so the motor is getting almost constant voltage.
This motor controller is also an inverter. It converts the DC voltage from the batteries into AC voltage that drives the motor.
The controller changes the voltage to determine what speed the motor spins at. If it supplies it with say 10v AC the motor will spin slowly compared to being supplied with 80v AC. The amount of current supplied determines how much torque the motor is producing. The higher the amperage, the higher the torque.
With this motor controller being an AC inverter, this opens up the possibility of regenerative braking. When the brake is pressed, it activates a switch in the controller which essentially closes the circuit of the phase wires which generates a current that gets converted back to DC voltage that charges the battery.
Design
Motor Mount
The motor is mounted to the bike by being sandwiched between two aluminum plates which get bolted to the frame
Battery Mount
The battery mount is made up of many pieces of angle aluminum which are welded together to create a box like case. This battery case is then bolted to the frame and the motor mount
Controller Mount
The controller is mounted to the frame via an aluminum plate
Concepts
Energy(J)
Energy is the capacity for doing work. It may exist in potential, kinetic, thermal, helectrical, chemical, nuclear, or other forms.
Power(kW)
Power is the rate, per unit time, at which electrical energy is transferred by an electric circuit. The SI unit of power is the watt, one joule per second. Electric power is usually produced by electric generators, but can also be supplied by sources such as electric batteries.
Capacity(kWh)
Energy capacity is measured in kilowatt-hours, or the ability of a battery to deliver a set power output (in kilowatts) over a period of time (in hours).
Torque(N/M)
The rotational equivalent of linear force. It is also referred to as the moment, moment of force, rotational force or turning effect, depending on the field of study.
Voltage(AC vs DC)
Current AC systems transmit power from generators at hundreds of thousands of volts and use transformers to lower the voltage to 220 volts. The term DC is used to refer to power systems that use only one polarity of voltage or current, and to refer to the constant, zero-frequency, or slowly varying local mean value of a voltage or current
Amps(A)
the base unit of electric current in the International System of Units (SI).
Magnetism
Magnetism is the class of physical attributes that are mediated by magnetic fields. Electric currents and the magnetic moments of elementary particles give rise to a magnetic field, which acts on other currents and magnetic moments. Magnetism is one aspect of the combined phenomenon of electromagnetism.
Piezoelectricity
Piezoelectricity is the electric charge that accumulates in certain solid materials—such as crystals, certain ceramics, and biological matter such as bone, DNA, and various proteins—in response to applied mechanical stress.
Electrostatics
Electrostatics is a branch of physics that studies electric charges at rest. Since classical times, it has been known that some materials, such as amber, attract lightweight particles after rubbing.
Problems We Are Addressing
How Can We Make It Affordable?
How Can We Ensure Component Compatibility?
Is It Legal?
What Are The Functions Of Each Component?
How Can We Make It Portable?
What Is The Time Frame For Our Project?
How Do We Mount The Components
How Will We Get Our Bike Components>
What Components Do We Need?