Project Status
Week of 01-30-19
Project is: ON TRACK
Although we have run into a few setbacks, primarily in the circuit design, we are still on track to be completed by the deadline.
Issues / Extra progress from last week:
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One issue we have run into since last week is finding an affordable and reliable source for the batteries
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Another issue we have run into is realizing how much more complex the circuitry for the motor driver is than anticipated
Accomplished this week:
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Ordered and began testing some of the different components for the motor driver circuit
Completed CAD modeling of existing KX65 components
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Started bike rebuild
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Sanded and painted the frame​
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Rebuilt fork seals and changed oil
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Replaced swing arm bearings
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Replaced linkage bearings
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Finished a concept for the battery pack
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Reconfigured the 18650 battery cells for better access to stock engine mounts​
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Batteries will be sealed inside a water resistance housing
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Machined or Waterjet from 6061 Al alloy
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3D printed prototype battery pack frame and fit checked okay
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![20190120_175733[1].jpg](https://static.wixstatic.com/media/cddaa5_40e248aa391e4047893ec27d8bef1a2c~mv2_d_3024_4032_s_4_2.jpg/v1/fill/w_266,h_354,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/20190120_175733%5B1%5D.jpg)
![20190120_175744[1].jpg](https://static.wixstatic.com/media/cddaa5_52ad555046dd462eb52d28ff65ce71f5~mv2_d_3024_4032_s_4_2.jpg/v1/fill/w_266,h_354,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/20190120_175744%5B1%5D.jpg)
![20190109_183614[1].jpg](https://static.wixstatic.com/media/cddaa5_17afc21d1f3344f297faef53083999b5~mv2_d_4032_3024_s_4_2.jpg/v1/fill/w_408,h_306,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/20190109_183614%5B1%5D.jpg)
![20190109_181203[1].jpg](https://static.wixstatic.com/media/cddaa5_9cc5670853b04502af84c603d26c9018~mv2_d_4032_3024_s_4_2.jpg/v1/fill/w_440,h_330,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/20190109_181203%5B1%5D.jpg)
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Replaced seat cover
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Weld repaired existing footpegs
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Powder coated footpegs and suspension linkage
![20190120_153557[1].jpg](https://static.wixstatic.com/media/cddaa5_bb73c24741654f669e1f116fe4cbb73a~mv2_d_3024_4032_s_4_2.jpg/v1/fill/w_274,h_365,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/20190120_153557%5B1%5D.jpg)
![20190111_105412[1].jpg](https://static.wixstatic.com/media/cddaa5_b15264225dc04c7e913e0ea4080d42da~mv2_d_4032_3024_s_4_2.jpg/v1/fill/w_461,h_346,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/20190111_105412%5B1%5D.jpg)
![20190114_201126[1].jpg](https://static.wixstatic.com/media/cddaa5_d12151008d2e4dbfbcee7b9db980d1f9~mv2_d_3024_4032_s_4_2.jpg/v1/fill/w_446,h_594,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/20190114_201126%5B1%5D.jpg)
![20190114_200726[1].jpg](https://static.wixstatic.com/media/cddaa5_a9c89f472a204bb2a3748f1500bedd98~mv2_d_3024_4032_s_4_2.jpg/v1/fill/w_401,h_534,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/20190114_200726%5B1%5D.jpg)
Battery Testing:
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​tested all 4 batteries purchased on Ebay, advertised as 3500mAh.
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Qty 2 batteries tested at 3300mAh and QTY 2 batteries tested at 2000mAh
Parts Ordered
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48V Brushless DC motor
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Front drive sprocket, 420 chain pitch
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Hand twist throttle potentiometer
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13S Battery Management System (BMS) **Received 1/28**
![20190127_181628[1].jpg](https://static.wixstatic.com/media/cddaa5_48711ff133434e3997f73e52743ab5ab~mv2_d_3024_4032_s_4_2.jpg/v1/fill/w_328,h_437,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/20190127_181628%5B1%5D.jpg)
Goals for next week:
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Continue working on the motor driver circuit
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Start writing code for the eBike controller
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Redesign a modular battery rack
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build a test battery pack
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coordinate with Jeremy Cornwall to use the Randolph campus waterjet
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Source aluminum plate needed for parts
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Verify round stock for spacers, turned on lathe at Williston campus