Project Status
Week of 02-06-19
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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Evaluation of the spot welder and assembly of the cells lead to a more traditional approach
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The battery pack was redesigned using interlocking 3D printed holders. These 6x1 battery holders will be configured to fit within an aluminum waterproof enclosure.
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Sourcing a company to make motor driver PCB
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Good price and reasonable turn around​ time
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Accomplished this week:
Battery pack design:
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​Battery pack was redesigned using a modular 6x1 frame.
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BMS position was determined andwiring was laid out
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New welded enclosure was designed with removable cover
Motor Mount adjustments:
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The 48v BLDC motor was 1mm larger in diameter than specified on the data sheet.​
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Internal Diameter was increased 1mm to compensate for larger outside diameter of the motor
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Clamp feature was rotated clockwise 75 degrees to allow more room for the battery and better access for tools
Component fit checks:
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The 48v BLDC motor was a tight squeeze due to the 1mm interference on the OD of the motor
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The lead on the back side will need a guard and clocked to be out of the way.
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The throttle potentiometer installed with no issues, the wires are long enough to reach the rear of the bike.
Electrical
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Continued circuit design
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Began preliminary circuit testing in MultiSim
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Began writing code for eBike controller
Goals for next week:
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Complete circuit design
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Begin sourcing motor driver PCB
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Continue code for eBike controller
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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
References:
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ebike school https://www.youtube.com/watch?v=u-4mKh1WaLo&t=463s