1986 VFR700F electric conversion

Discussion in 'Mechanics Garage' started by frodus, Mar 7, 2008.

  1. invisible cities

    invisible cities New Member

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    A very interesting project. Kudos on this build!

    If I could put in a request, a few larger images detailing the work would be most appreciated.

    Thx!
     
  2. Heatmizr

    Heatmizr New Member

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    Just seeing this for the first time - Rock On! I actually began researching this idea from scratch for myself (but maybe starting with an e-bicycle) just months ago, so I believe you were a year or two ahead of the times. However, I have no EE degree, & no machine shop, although I have built a very comfortable garage to work in. Additionally, and just as relevant, having started a family recently I have no FREE TIME to see this come to fruition.
    That, and after seeing so many easy bolt-on kits available for bicycles I kind of lost my urge to go create one from scratch that would be most likely an ugly, home-made conglomeration of parts.

    I am however more interested in the results of your efforts to register your eVFR out there. I know here, any motorized bicycle that does more than 30 mph has to be registered as a motor vehicle which I find a huge disincentive. (could probably lie or gear it to top out at 29mph I suppose). Same for any ICE engine bicycle over 50cc I think.
    Further, I am not sure how the law reads for an actual motorcycle, if its the same as above.

    I DO know that a guy here got in trouble after he converted an old Mercedes diesel to run on cooking oil, for getting around the gasoline tax for motor vehicles. Not sure of the law there but I saw it as a tragedy that they actually came after him for this, and he paid a pretty large fine. All for being innovative and doing something he saw as "the right thing to do".
    I don't know how they are going to handle the new all-electric cars coming out now, they had to have addressed that.
     
  3. mozilla.v4snob

    mozilla.v4snob New Member

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    Fyi

    Just a quick FYI.

    Matt Dieckmann, who started this thread, passed away last August. He was riding one of his e-bikes around town and collided with a prius, of all things. Hats off to a true pioneer.

    link to obit:
    Matt Dieckmann | PressDemocrat.com
     
  4. crustyrider

    crustyrider New Member

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    that is truly saddening...

    I know its 5 months later ..... my condolences to the family. I hope if there is a way his father and family can keep his business around....
     
  5. frodus

    frodus New Member

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    Actually, I (Travis Gintz) started this thread and I'm still around.

    Matt was a friend of mine though, and he did pass away last year after a vehicle turned in front of him.
     
  6. frodus

    frodus New Member

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    They're all on my website:
    http://www.evfr.net

    gallery is here:
    eVFR.net Photo Gallery - Home
     
  7. crustyrider

    crustyrider New Member

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    Glad to hear you ok...and Sorry to hear about your friend..... how goes the build?
     
  8. frodus

    frodus New Member

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    Slow but sure. Testing batteries for a TTXGP bike. The bike is in a friend's shop for mounting of components. Should be late spring.
     
  9. frodus

    frodus New Member

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    Wow, it sure has been a while, still not finished (never enough time). Time for a little update (thanks for reminding me Sebspeed).

    I do consulting on the side and have been working with the community on designing systems, so I kinda put this off. While doing that, I got a nice Battery Management System from Elithion. I've assembled a few test packs and really like how it works. I also decided to scrap the brushed DC motor (K99 motor) and go with a brush-less AC Induction motor. I started with an AC15 motor and Curtis 1238-6501 motor, but a sold that and upgraded yet again to an AC20 motor and 1238-7501 controller. This gives a little more HP and higher running voltage and higher RPM of the motor. This gives more HP than the K99 and a higher RPM. I got some motor mounts machined, mounted the new motor and am now working on trying to cram all of the batteries inside the frame. I bought some UHMW plastic (3/4" thick, 4x8' sheet) to fabricate the cell-holders. I'm not using the cheap red plastic holders shown below, I want something more finished looking.

    Anyway, here are some pictures:

    Testing some batteries (testing for capacity so I can match cells/test them before installing):
    [​IMG]

    Batteries assembled into test pack:
    [​IMG]

    BMS installed on the pack:
    [​IMG]

    BMS controller:
    [​IMG]

    AC15 with mounts:
    [​IMG]

    Mocking up the battery pack:
    [​IMG]

    AC20 mounted:
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Drawing of one of the battery packs (I may change this):
    [​IMG]

    Prototype pack made of UHMW and milled on a CNC router table:
    [​IMG]

    [​IMG]



    So anyway, there's the update. I got some of the fairings mounted so I can accurately design the battery pack. A heat sink for the controller is being machined and it'll go underneath the bike and stick out just a little bit from the fairing, right where the original exhaust went. It's a perfect place for airflow. Once I get the controller and heat-sink back, I can really start mocking things up with some foam-board and hot-glue. Once I figure out the maximum pack size, I can start to fit batteries inside it in CAD and send to my fabricator to CNC the final pack. Then we'll weld up an aluminum box for it, and start assembly.
     
  10. invisible cities

    invisible cities New Member

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    Thanks for the update. This is some Must See TV!

    Please keep us posted.
     
  11. frodus

    frodus New Member

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    Got my forks rebuilt last week and drilled out my triple clamp to attach a bar riser I found to mount some Spiegler superbike handlebars. Only 1 problem, the brake line isn't long enough, so I need to order some new lines. Kind of a bummer, but now I can upgrade to braided brake lines quick would be good since I'm running with 25+ year old lines.

    Got me thinking about just replacing the front master cylinder too. They're harder to get parts for. Since I don't NEED anything immediately, I'll let things go until I get the bike running because I'll probably want to rebuild the front and rear brake slaves, replace brake lines, replace pads and put new brake fluid in there. It'l be a good nice weekend project in the spring.

    But at least it's back together. I'll throw the old bars on there for now until I get the lines. Probably be a couple months because I don't really feel like rebuilding the brakes too. At least I can get back to the battery pack I keep putting off.

    So here's the current state:

    photo 2.jpg photo 3.jpg photo 5.jpg photo 4.jpg photo 1.jpg
     
  12. drewl

    drewl Insider

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    I like it. Looks kind of motard-ish now.
     
  13. McViffer

    McViffer New Member

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    Any Progress?
     
  14. frodus

    frodus New Member

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    yeah, working on finalizing the Solidworks CAD drawing of the battery pack.... in a week or so it'll go to fabrication and then we'll start welding up the battery box and start wiring things up.

    www.evfr.net
     
  15. frodus

    frodus New Member

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    I’ve still been working on the 12V test pack and wiring while parts are fabricated. I got the BMS controller + cell boards talking and shutting off the charger correctly.

    Working on a schematic, but here’s what I’ve got so far:

    Ordered some optically isolated FETs to wire to the throttle since the Curtis I/O is not isolated. This will allow me to limit throttle as I reach my discharge current limit (DCL). It’s an analog output from the BMS, the more that output is driven, the less throttle I get. I can also limit regen by using another optically isolated FET on the CCL line and limit the Brake input.

    Got the delta-q algorithms set up and wiring figured out. There’s an enable line that is grounded to B- when you want it to run, and ungrounded when you disable it. I control this with a little automotive relay connected to the HLIM (High Voltage Limit) on the BMS controller. This allows the BMS to turn the controller on/off when cells go high.

    There’s a Relay inside the DeltaQ that turns on when you plug it in. I’ve taken the 12V always on from my Surepower DC-DC converter and wired that to the COM of the relay contacts. N/O goes to my V-Source of the BMS controller, so when it’s plugged in, it powers the BMS but nothing else. The N/C contacts go through the Ignition, and to the Key-switch input on the DC-DC converter. The switched output of the DC-DC goes to the V-Load input to power the BMS. It also goes to my 12V system (lights, signals, etc.).

    The Curtis does its own Contactor control and pre-charge, but the BMS needs to be able to turn on/off the load. I can do that with DCL limiting throttle, but nothing disables the controller in case of a fault. I’m thinking I’ll use the LLIM line to drive a small 12V coil 150VDC contact to switch B+ and pin 1 (enable) of the controller.

    I also wired up Canbus, changed the Elithion to ID 7E0 for OBD-II PIDs. I connected a Bluetooth-OBD-II dongle, paired with my Android tablet, started a program called Torque and imported a list of PIDs that I got from Elithion and added some Gauges. Screenshot:
    [​IMG]

    So I’ve got the logic all figured out for the 4 main electronic pieces (controller, DC-DC, BMS and charger)… so after that, it’s on to the lighting/existing electrical.

    Other pics of the bike below. Have fairings mounted, starting to sand and get ready for paint:
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  16. Scubalong

    Scubalong Official Greeter?

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    Niiiiiiiiiiiice :hail:
    Keep us posted please.................:pop2:
     
  17. mello dude

    mello dude Administrator

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    Hey Frodus, good to hear from you - I really like your work going on here..
     
  18. frodus

    frodus New Member

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    Thanks guys! I appreciate the support! It's taken a while (but what project doesn't?).... and I'm finally getting near the finish line.

    Pic of the fibarglass faux tank (just 1/2 of it, used as a cover) with filled in gas cap:
    [​IMG]

    Pic of the battery pack:
    [​IMG]
     
  19. frodus

    frodus New Member

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    Lots of small cracks in my airtech fairing (was secondhand) so we've spent some time filling those and making it stronger. I've been focusing a lot more on the electrical and have full integration with everything. The battery management system monitors cells and current and backs off the throttle on the controller if I go over limits, and while charging it shuts off the charger or disables regenerative braking.

    And because I'm geeky enough to even build the electric motorcycle in the first place, I had to take advantage of the fact that Torque can "Tweet" to twitter :)


    [​IMG]
     
  20. frodus

    frodus New Member

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    Update from my blog:
     
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