Electric bike based on brushless motor
We collect the electrobicycle
For the basis of the driving mechanism of his electric bike, the author took the ready set for reworking a skateboard into an electric board. It can be purchased at Chinese sites complete with engine and belt transmission within $ 100. The engine is provided for them 24-volt, which works without brushes. For such devices, this is the most profitable design, the weight is about 500 grams, and the power is 1800 W! Of course, with such characteristics, he has enough to easily pull the bike along with the rider.
Step one - do the electric drive on the suspension
First of all, we attach the mounting platform for the engine and the belt drive to the suspension axis. Next, fix the wheel from the skateboard with the gear on the axis of the suspension.
Now you need to correctly set the mounting platform for the engine. Unfold it perpendicular to the vertical axis of the suspension, and tighten the clamping bolt with a hexagonal key.
Install the engine on the seat, tighten it with four screws and put on the small gear for the belt drive.
Step two - connect the electrical circuit
The suspension assembly is ready; now it can be connected to the batteries via the speed regulator. They are connected in series. The author of the video added a resistance switch to the circuit in order to be able to smoothly change the voltage and trace the operation of the engine at the same time.
We disconnect the rheostat (we will not need it anymore), and connect the radio-controlled controller-handle with the receiver-transmitter. This equipment is used by skateboarders to control the electric boards. A convenient trigger on the handle allows you to control such a device easily and naturally.
Step three - fix the driving module on the bicycle frame
The installation of such a module has its own characteristics. If it is fixed on the bicycle frame tightly, the wheel from the skate can wipe the bicycle tire, and the engine can overheat from excessive pressure and burn. In the free position, such a suspension will hang out as unnecessary ballast while driving, especially along country roads.For functional hardware, a pivot point and a lever mechanism that will press the skateboard wheel to the tire is necessary. We are going to do it now.
Raise the rear fender of the bike higher to place the propulsion module in its place.
The suspension should be slightly trimmed by removing the unclaimed second axis from it. Clamp the device in a vice, and the grinder (LBM) cut it flush with the mounting platform for the board. We clean the cut edges with a grinding disc.
From the sheet of metal cut the protective cover for the moving module. Mark it to the size of the device, and cut the grinder. To fix the engine, make holes for the mounting plate, and sit it on the bolts.
The movable module will be attached to the frame by means of a small but powerful loop. It will be the axis of our device. From the back of the protective cover we fix the loop with a welding inverter. We clean the seams with a grinder.
Using a piece of a conventional door hinge, we make a clamping clamp for fasteners on the frame. Protect the cover with a loop paint spray in the color of the bike frame. Fasten it on the bolts to the device of the movable module.
The entire device is mounted through a powerful bolt. We drill a hole in the loop and frame, we press through it the bolted joint with open-end wrench and spanner wrench. It is necessary to adjust its position so that the skateboard wheel is exposed parallel to the wheel ramp, and moves with it in the same plane.
Step Four - Preparing the Lever
The clamping mechanism is made in the form of a small lever. It relies on a rigid spring defined in compression.
We fix the bolt on the cover, which will restrain the movement of the spring, and will not allow it to come off.
We make the lever of the profile tube 15x15 mm. We mark an angular cut on one end of it, on the other - a bend by 90 degrees. We make cuts with a grinder and we weld the joint with a welder.
From the aluminum plate we make a crimping clamp to secure the lever on the frame. Cleaning the seams, you can proceed to painting.
Step five - install an electrician on the bike
We place battery banks on the diagonal cross-frame. We rest them in a vertical rack and tightly wrap tape, leaving open only the terminals of the contacts. Install the lever on the frame, fasten the clamp on the bolted connection, and push it with a screwdriver.We put the spring on the seat, and check the force of the clamp to the tire.
Under the saddle fasten the plastic wing through the crimp bracket. On the protective cover we glue the double speed tape with double adhesive tape. Connect the contacts of the engine and regulator. Wire spikes are insulated with shrinking. We glue the receiver with a transmitter for radio-controlled control nearby.
Cut the wiring to connect the batteries and the movable module. Using a stripper, you can crimp the terminals and strip the insulation. We wind the long wiring around the frame and solder the terminal block for connection to the speed controller. We tie a loop of wires with nylon ties The device is ready to launch!
Raising the driving rear wheel on the bike support, you can try to start our electric bike. The advantage of the electronic speed controller is that it allows you to accurately reproduce the specified voltage up to a complete shutdown. They are often used for electric boards and model cars.
An electronic sensor mounted on the front of the cans will help in time to monitor the charging of the batteries.For charging, we use a professional device for lithium-ion and polymer batteries with a voltage stabilizer.
It's time to sit on the electric bike and ride somewhere, having tried the duration of the batteries. Despite the absence of a rear brake, turning off the power to the engine should contribute to a smooth stopping of the electric bait.
Well, the most important of the advantages of this type of transport is that if you suddenly have batteries, you can always pedal to the nearest source of electricity, and continue your exciting journey lightly!