Build Your Own Electric Motorcycle | Build Your Own

Build Your Own Electric Motorcycle

Authors: Carl Vogel

Published: June 2009

eISBN: 9780071622943 0071622942 | ISBN: 9780071622936

Contents

Preface

Acknowledgments

1 Why You Need to Get an Electric Motorcycle Today!

Convert That Motorcycle!

What Is an Electric Motorcycle?

Electric Motors

Batteries

Controllers

Electric Motorcycles Are Fun to Drive

Electric Motorcycles Save Money

Operating Costs

Purchase Costs

Safety First

Electric Motorcycle Myths: Dispelling the Rumors

Myth 1: Electric Motorcycles Can't Go Fast Enough

Myth 2: Electric Motorcycles Have Limited Range

Myth 3: Electric Motorcycles Are Not Convenient

Myth 4: Electric Motorcycles Are Expensive

Disadvantages

Time to Purchase/Build

Repairs

My Passion

Coolfuel Roadtrip

2 Electric Motorcycles Save the Environment and Energy

Why Do Electric Motorcycles Save the Environment?

Environmental Benefits

Save the Environment and Save Some Money Too!

Energy Efficiency

Electricity Generation: How Is It Made?

Steam Turbines Are the Leader

Natural Gas

Petroleum

Nuclear Power

Hydropower

Geothermal Power

Solar Power

Wind Power

Biomass

Efficiencies of Power Plants

U.S. Transportation Depends on Oil

Emission Facts

Further Economic and Competitive Matters

Economic Benefits

Summary

EPA Testing Procedures for Electric Motorcycles

3 History of the Electric Motorcycle

Steam First!

Copeland Steam Motorcycle

Early 1900s

The Early 1940s

1970s–1990s

Late 1990s

Vogelbilt Corporation's Electra Cruiser Was in Coolfuel Roadtrip

Latest News

The Idea

The Prototype

Future Plans

The KillaCycle—Bill Dube Breaks NEDRA Records

E-mail from Bill Dube

New World Record at Bandimere—7.89 Seconds (Also 174 mph!)

Ducati Project

Vectrix Corporation

The Vectrix VX-1

Summary

4 Current Electric Motorcycles on the Market

Electric Motorcycles: Cool and Green

Eva Håkansson's Electrocat Electric Motorcycle

KillaCycle and KillaCycle LSR Electric Motorcycles

Zero Motorcycles

Brammo Motorsports

Voltzilla: DIY Electric Motorcycle by Russ Gries

Electric Motorcycle Conversions: Easier Than You Think

KTM "Race Ready" Enduro Electric Motorcycle

Honda and Yamaha to Make Electric Motorcycles in 2010–2011

EVT America

Summary

5 Geometry: A Basic Lesson on Rake, Trail, and Suspension

Rake

Trail

Fork Angle

Fork Length

Fork Dive

Travel

Spring Rate

Rear Suspension

Rear Suspension Styles

Twin-Shock Regular H Swingarm

Monoshock Regular H Swingarm

Hybrid Twin-Shock H Swingarm

Monolever Suspension

Conclusion

6 Frame and Design

Choosing a Frame and Planning Your Design

Selecting a Frame Dos and Don'ts

Optimize Your EV

Standard Measurements and Formulas

EV Weight

Remove All Unessential Weight

During Conversion

Weight and Acceleration

Weight and Climbing

Weight Affects Speed

Weight Affects Range

Remove the Weight But Keep Your Balance

Remember the 30 Percent Rule

Streamline Your EV

Aerodynamic Drag Force Defined

Choose the Lowest Coefficient of Drag

Frontal Area

Relative Wind Contributes to Aerodynamic Drag

Aerodynamic Drag Force Data You Can Use

Wheel Well and Underbody Airflow

Roll with the Road

Rolling Resistance Defined

Pay Attention to Your Tires

Use Radial Tires

Use High Tire Inflation Pressures

Brake Drag and Rolling Resistance

Rolling-Resistance Force Data You Can Use

Less Is More with Drivetrains

Drivetrains

Difference in Motor versus Engine Specifications

Going through the Gears

Manual Transmission versus Chain or Shaft Drive

Drivetrains and Fluids

Design Your EV

Horsepower, Torque, and Current

Calculation Overview

Torque-Required Worksheet

Torque-Available Worksheet

Why Conversion Is Best

Sell Your Unused Engine Parts

Equipment Required for Motorcycles (Including Limited-Use Motorcycles)

Brakes

Horn

Muffler

Mirror

Windscreen

Handlebars or Grips

Seat Height

Tires

Lighting Devices and Reflectors

Speedometer

Fenders

7 Batteries

Battery Overview

Battery History

Early Pioneers in Battery Technology

Battery Types

Starting Batteries

Deep-Cycle Batteries

Industrial Batteries

Sealed Batteries

Nickel-Cadmium Batteries

Lithium Batteries

Battery Construction

Battery Case

Plates

Sulfation

Terminal Posts

Battery Group Size

Inside Your Battery

Active Materials

Electrolytes

Overall Chemical Reaction

Discharging Chemical Reaction

Charging Chemical Reaction

Electrolyte Specific Gravity

State of Charge

Gassing

Equalizing

Cell Balancing

Battery Explosions

Battery Calculations and Capacity

Current and Amperes

The Volt

Power or Watts

Battery Storage Capacity

Battery Configurations: Series and Parallel

Battery C Rating: C/20, C/3, C/1, etc

Available Capacity versus Total Capacity

Energy Density

Cold-Cranking Amperes

Depth of Discharge (DOD)

Basic Battery Spreadsheet

Battery Disposal

Environmental Benefits

General Battery Requirements

Purchasing Specifications

EV Battery Operating Requirements

Safety

Electric Shock

Battery Solutions Today

8 Electric Motors

History of Electric Motors

Choosing the Right Motor for You

Electric Motor Horsepower

Some Simple Points and Notes

Some Basic Terms to Know

DC Motors

DC Motor Basic Construction

Armature

Commutator

Field Poles

Brushes

Motor Timing

DC Motor Types

Series DC Motor

Shunt DC Motors

Compound DC Motor

Permanent-Magnet DC Motor

Universal Motor

AC Electric Motors

A Couple of Terms You Should Know

Single-Phase Induction Motor

AC Synchronous Motor

Polyphase AC Induction Motor (Three-Phase AC Motor)

EV Motor Selection

Permanent-Magnet DC Motor

Series-Wound Motor Examples

Calculations and Formulas

Calculating Horsepower

Calculating Full-Load Torque

Conclusion

9 The Motor Controller

Controller Overview

Basic Controller Explanation

Multiswitching Control

Solid-State Controllers

Modern Electronic Controllers

Undervoltage Cutback

Overtemperature Cutback

AC Controller

Controllers on the Market Today

Series-Wound DC Controller

Curtis Instruments

ZAPI Controllers

Navitas Technologies

Alltrax DC Motor Controllers

AC Controllers

Curtis Instruments AC Controllers

ZAPI AC Motor Controllers

Metric Mind Engineering

Conclusion

10 The Charger and Battery Management System

Charger Overview

Charger Checklist

Charging Times

Charging and Optimization

End of Charge Cycle (Termination)

Charge Efficiency

Charging Methods

Opportunity Charging

Charge Efficiency

Battery Discharging Cycle

Battery Charging Cycle

The Ideal Battery Charger

Charging between 0 and 20 Percent

Charging between 20 and 90 Percent

Charging between 90 and 100 Percent

Charging above 100 Percent (Equalizing Charging)

Battery Chargers Today

Zivan Charger

Manzanita Micro PFC-20

Curtis Instruments

Brusa

Battery Management Systems and Battery Balancers

Battery Balancers

Battery Management Systems

Conclusion

11 Accessories and Converters

Communications

Battery "Fuel Gauge" and Monitoring

Battery Indicator

Xantrex Link 10

Curtis Series 800 and 900 Battery SOC Instrumentation

Voltmeter

Ammeter

DC-to-DC Converter

Vicor DC-to-DC Converter

Curtis DC-to-DC Converter

Conclusion

12 Electrical System and Wiring

Electrical Safety

EV Electrical System Components

Main Circuit Breaker or Quick Disconnect

Main Contactor

Reversing Relay

Safety Fuse

Low-Voltage, Low-Current System

Throttle Potentiometer

Shunts

Wiring Your System Together

Wire

Cable Connectors

Wire Covers

Routing

Grounding

Electrical Wiring Diagrams

Conclusion

13 The Build

Conversion Overview

Before the Conversion

Help on Your Project

Arrange for Space

Arrange for Tools

Arrange for Purchases and Deliveries

Conversion

Things to Keep in Mind

Frame

Purchasing the Frame

Purchase of Other Components

Prepare the Chassis

Mechanical

Mounting Your Electric Motor

The Critical Distance—Motor Interface with Wheel

Support for the Electric Motor

Creating Battery Mounts

Electrical

High-Current System

Low-Voltage System

Battery Wiring

After Conversion

System Checkout on Blocks

Trial Test Run

Moving Forward

14 Sources

More Information over Time

Clubs, Associations, and Organizations

Manufacturers, Converters, and Consultants

Suppliers

Conversion Kits

Conversion Plans

Motors

Controllers

Batteries

Chargers

Electric Motorcycle Sales

Other Parts

European Manufacturers, Converters, and Consultants

Books, Articles, and Papers

Publishers

Newsletters

Online Industry Publications

Grassroots Electric Drive Sites

Federal Government Sites

State and Community-Related EV Sites

General Electric Drive (ED) Information Sites

Notes

Index