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Electric Tricycle
by ben_k on March 28, 2013 Table of Contents Electric Tricycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro: Electric Tricycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1: Why Did I Build This? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 2: An Overview of the Tricycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 3: Preparing the Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 4: Building the Frame: Steel Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 5: Machining a Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 6: Modifying the Internal Gear Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3 3 5 7 8 9
Step 7: Building the Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 8: Building the Frame: Pivoting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Step 9: Building the Frame: Making Lots of Aluminum Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Step 10: Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Step 11: Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Step 12: Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Step 13: The Rest of the Mechanical Things . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Step 14: Building a Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Step 15: Electrical Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Step 16: Videos, Conclusion, Linkdump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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trigger shifter mounted on the handlebars Via another chain reduction, the output of the gearbox turns a custom spur gear differential , which splits the torque from the motor to the two back wheels. Each of the back wheels is equipped with a set of disk brakes, which are actuated with a double-pull brake lever on the handlebars. Steering is accomplished very similarly to a bicycle or motorcycle. In addition to the handlebars turning the front wheel, the front half of the trike's frame also tilts side to side. The tilting motion allows for fast, stable turns, which would not be possible if the frame were rigid.
Image Notes 1. Wheel 2. Disk Brake 3. Battery under here 4. Differential 5. Gearbox 6. Wheel 7. disk brake 8. Motor
Image Notes 1. Assuming your motor controller can provide all of your motor's stall current, your torque vs rpm curves look like this. Each different curve represents the torque at the wheel vs wheel rpm for a different gear. 2. Dashed vertical lines indicate the optimal points to shift gears 3. Torque 4. RPM
Image Notes 1. My controller can't supply all of my motor's stal current. This is what the motor curves look like with current limited to 1/2 stall current 2. Once again, you shift at the spots the curves cross. This is where you actually get higher torque at the wheel in a taller gear than a lower gear. Image Notes 1. Power 2. RPM
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Image Notes 1. This is what things look like when limited to 1/3 stall current Image Notes 1. Notice with only 1/2 stall current available, you still get the same peak power. For permanent magnet motors, peak power occurs at 1/2 stall torque and 1/2 noload RPM. Since torque is proportional to current, this is also at the 1/2 stall current point.
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Image Notes 1. This rod holds the tabs to the correct spacing
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Image Notes 1. The set screw here, and one on the opposite side hold the rod in place 2. This end fits inside the tubing
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Image Notes 1. I put some scrap aluminum underneath, so I wouldn't mill into the table.
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Image Notes 1. Each gear has a pair of bronze bushings pressed into it
Image Notes 1. This is the basic gear configuration inside the differential
Image Notes 1. I faced the aluminum round on the mill before turning the endcaps.
Image Notes 1. If you print out engineering drawings, you don't have to constantly refer back to your computer
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Image Notes 1. This aluminum fixture holds all the rods together for facing
Image Notes 1. It also stops the vice from grunging up the nice smooth shafts
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Image Notes 1. I added aluminum spacers later to axially constrain the gears
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Image Notes 1. This tapped bar holds the right half of the top plate
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Image Notes 1. I had to use these bolts instead of socket cap ones, because the socket caps protruded too far.
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Image Notes 1. I epoxied the fiberglass top to the plastic frame, also mounting bolts into the frame.
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Image Notes 1. I had to cut out a little notch to get the bolt head to fit
Image Notes 1. The brakes are easiest to adjust without the tires on
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The final mechanical step was modifying the motor. The original motor I had was already ready to use, but it ended up having some internal shorts. This lead to many hours of troubleshooting with local motor expert Shane , and finally replacement with a new identical motor. To prepare the motor, first I cut off the shaft protruding from the back end. This shaft if for attaching propellers to, so it was unnecessary I then milled a flat and a dimple 90 degrees apart from each other in the drive side of the shaft. When set screws on the drive sprocket are tightened into the flat and dimple, they stop the sprocket from rotating independently to the shaft. The dimple also stops the sprocket from shifting axially.
Image Notes 1. You can just see the edge of the thrust washer
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I have entered this Instructable in two contests, the UP! contest and the Make-To-Learn Youth Conest, so please vote if you like this.
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