Top panel breaks

I have started to think about how to supports and breaks on the top panels. Although I’m still at very early days I thought it will be sensible to make the controller cover made from aluminium the main structural component of this assembly. The top, side, front and rear replacement panel pinning to a sub-chassis….

Cover redesign

3 issues that seem important at the moment: Access to the control panel – Currently thinking of a hatch over the control panel that hinges from the front (pivot point arrowed in red). Potentially this could be locked. Air flow to the bottom of the controller – Marked in green thinking that it would be…

Switch panel

Need to start mounting some of the components that are just hanging around at the moment. I have put something together in CAD quickly and spent a bit of time with the printer. Have tried a new material rPETG that has a substantially higher temperature and water resistance and has excellent ductile strength making it…

Isolator carriage v2 printed

I know I should be used to it by now (after all I see it happens all the time in University and in the design industry) but it still amazes me that I can print designs into reality that only exist on a computer. Anyway, I managed to push out a rough print overnight to…

Isolator carriage v2

Have made some changes to v1 design of the isolator carriage. A bit more cable management and some amendments to the BMS to ensure the charge input cables are orriended correctly, etc. Need to print the design to double check it maybe get some advise of the management of the cables. Currently the high and…

Isolator carriage v1

Having had some small issues with dimensional accuracy I have finally started to get some results on the bigger prints and I am finding new uses for the printer. Originally I planned to stick the BMS, charger, and precharger components onto a thin board with 3M double sided tape to isolate it from the batteries….

300mm cuts

Have started to think about the opportunity to 3D print panels rather than metal form them. The more I think about it the more it makes sense. Plastic doesn’t conduct electricity, useful trait on an electric bike… and the production will be easier for my CAD skillset. Having had the printer for a while I…

Rear battery box cover v2

I have spent an evening making some changes to the design of the original battery box to give better clearance for the cables I originally planned to through the bottom of the box because that is where the BMS used to be but now that it is better placed above the battery amendments need to…

Mock under bracket

Interesting to see the growing form of the battery as a whole with the under bracket mocked up in card. All seems to be good. The contactor can be easily removed and replaced and when in position both the contactor and the DCDC convertor clearance is good. On issue is the cable routing. The high…

Underside mounts & protection

Started to think of mounting points for the lower covers and extra protection for the contactor and DC/DC convertor components under the battery case. Decided to combine them. thinking it needs to be quite strong so some folded 3mm alu will make for easy fabricate but maintain strength. The extra thickness should make the mounting…