Archive for August, 2012


SuperScoot: An Electric Scooter Upgrade

OK, I’m going public on this.  I just picked up this little puppy last weekend:

It’s a Chinese electric scooter with a DOA brushless hub motor.  It has some nice detailing, though, like these gauges.  Note the nice little chrome voltmeter:

So, the options are to try to fix the hub motor, which didn’t go too well last time I tried it, or to replace the hub motor with a new one, which should bolt right in…  short money for a stock 700W replacement, but who wants a 700W motor?  Not I.  When you start looking at the big hub motors, it gets pricey fast.  The third approach would be to dispense with the hub motor entirely and replace it with something with some balls.

Which I just happen to have lying around.  Heh…  heh…  Or should I say, “muWAHhahahaha”?

The idea of bolting in a 10kw ETEK to a scooter is more or less heresy in the scooter circles…  they all seem to like the hub motors, but I can’t figure out why.  There’s a crap-ton of room inside those scoots, and you don’t even have to do things pretty, since they’re all covered up.  And with a non-hub motor I can mess with gearing.  The ETEK fits in like a dream, thus:

There’s more than enough room for a nice little lithium pack where the lead went…

I just bought a Yamaha Chappy rear wheel, complete with drum brake and sprocket.  The measurements I was able to find appear to be a perfect fit, but I won’t know for sure until I get it.

Update:  The wheel fits like a glove.  Here’s the layout for the motor mount:

 

Events Update: Sept/Oct 2012

Wow…  busy couple of months about to start.  Here’s the rundown.

Monday, Sept 3:   Live interview about eBikes, EVs and Personal Electric Vehicles on the Sustainable Living Program that airs live on WMNF 88.5 (Tampa FL).

Sunday, Sept 9: Rice-O-Rama, Japanese Motorcycle Meet in Oxford MA.

Sunday, Sept 16: Alternative Energy Day (Mt Washington Auto Road)

Monday, Sept 17: The IOM Cleantech Roadshow at MIT.

Sunday, Sept 23: Boston Plug-In Day (Boston Common)

Sunday, Sept 30: Japanese Car and Motorcycle Day (Larz Anderson Auto Museum)

Saturday, Oct 13: Mini-Maker Faire, Somerville MA.

Sunday, Oct 21: Green Day (Larz Anderson Auto Museum)

I’m going to do my best to make it to all of these…  hope to see you there!

The R5e- Before and After

I finished up the punchlist today, and was looking through my old pile of photos.  This is amusing.

Here’s the bike, when I first brought it home.

 

And here it is today:

 

More photos to come, once I have a chance to put together a proper shoot.  But I’m happy.

2012 Lightning First Ride – Video (via motorcycles.com)

Possibly one of the most hysterical road test videos on YouTube (I think he likes it…):

A lot of groundbreaking comments this past week…  from the story on Motorcycle.com: “The Lightning, without a doubt, is the fastest motorcycle I’ve ever ridden – gas or electric.”

Zero ZF9 vs Brammo Empulse R: Talking With Wes Siler

First, a little context.

I’ve been riding motorcycles since around 1970.  I like riding motorcycles a lot more than I like talking about them, working on them, reading about them or playing with all the shiny gadgets on them.  I have peculiar tastes in motorcycles.  I bought a single-cylinder 600cc with only a kick-starter back when electric start was the latest new refinement in street bikes, and, not only did every bike have one, but they started omitting the kick starter entirely.  When I bought the bike in 1987, the salesman told me “You’re the only asshole in New England who’d buy this bike, you know.”

I like tube steel frames designed in the 1970s.  I’m not a fan of dials, gauges, lights and beepers on a motorcycle.  I like light, nimble tight bikes that can do curves gracefully, and I really enjoy riding a speeds of around 50-80mph on the street.  That’s because those are speeds that I can have the most fun at, and stay alive if things go horribly wrong.  I’ve been on bikes when things have gone horribly wrong, and as much as I love speed, I don’t want to do that anymore.

For me, riding is a complete physical and emotional experience.  Riding motorcycles is far more than specs on paper.  Even the slightest nuance can make the difference between a bike I love, and a bike I can’t wait to park.

As a result, even from the very beginning, I found myself modifying my bikes.  I can’t claim to be a “builder”, but I’ve never been satisfied with the compromises that manufacturers make to satisfy a broad audience. The final manifestation of that is the R5e.  I wanted to find out what a high-powered electric bike felt like to ride, there was nothing out there even close to what I was looking for, so I modified a great old bike myself to find out. The result, if you don’t mind my sayin’ is a bike that goes as fast as an Empulse…  maybe not as far, but definitely as fast.

So, I’m interested in what makes a great bike, well, great.  I want to know how to build a better bike.

Fast forward to the release of the Brammo Empulse R, and the Hell for Leather review that came out this week.  Here’s a guy who’s ridden both the Empulse and the Zero ZF9, and has a completely different response to the Brammo.  Much as I wished I could dismiss his opinions as party-line anti-electric in his RideApart video as the viewpoint of a die-hard gas biker unwilling to consider new technology and the hurdles that come with it, there was a big part of that video that was painfully true.  I simply couldn’t dismiss it.  Electric motorcycles are still very much a fringe phenomenon.  Now, this same guy gets on the Brammo Empulse R, and has a completely different response.  “The Empulse is simply a more pure experience than any gasoline-powered bike could ever be.”

Here’s the thing.  If you look at the specs, there’s not a whole lot of difference between the two bikes.  Seriously.  So as someone who fancies himself a builder of motorcycles I find myself asking what accounts for this huge difference in response from the rider of these two similar builds,  if it’s not the specifications of the bike?

So, I asked the guy.

This is Wes Siler, the main force behind Hell for Leather, and his response, word-for-word to my questions about his review.  My question:

It seems like the bikes are pretty close on paper, so the difference in your response to the two is a little confusing. Why do you think the Empulse worked so much better for you? Was it the handling, maybe the little bit of added range? Is the acceleration hugely better? (I can’t find numbers for that…) Is it the transmission? That would be HUGE, it’s a major source of discussion in the forums, and a big deal when Brammo made that decision. Or maybe just the simple fact that you didn’t get stranded lol?

His answers:

Why did the Empulse work so much better for you?

…as a serious motorcyclist, I just want a serious motorcycle, not a loose conglomeration of parts that are vaguely capable of transporting me a short distance. The Empulse is a full-realized, consumer-ready product that goes and stops just like an ICE bike and handles even better than one. There’s no cut corners and no bullshit. 

Was it the handling, the added range?

Yes and Yes. On the Empulse, the handling is just out of this world. That’s because Brammo fitted real motorcycle parts like actual motorcycle tires, actual motorcycle suspension (fully adjustable, fancy stuff), actual motorcycle brakes (radial Brembos) and actual motorcycle wheels (forged Marchesinis). But, also because they spent a huge amount of time developing the chassis on the kind of roads actual motorcycles are ridden on. 

Not lying about the range helps too. 

Is the acceleration hugely better?

Yes. Pull away from a stoplight on the Zero and you’d be in a very tough, head-to-head drag race with a 50cc scooter up to about 35mph. Pull away from a stoplight on the Brammo, slipping the clutch to keep it in the powerband, and you’d beat pretty much any car and could even get the edge on some ICE bikes. Thanks to the gears, that continues up to 100mph+. It’s not going to give an RSV4 a run for it’s money, but it’s enough to ride it like a real motorcycle. 

Is it the transmission?

Yes. It seriously does build back in a much-needed element of man/machine interaction. Thanks to it, the Empulse feels like a motorcycle. Without it, the Zero feels like a transportation appliance. 

Where you just pin the Zero and try not to be too disappointed, on the Empulse you’re chasing a powerband, downshifting as you enter corners to use the engine braking and to get ready to achieve maximum acceleration out, and just generally using both hands and both feet and climbing all over the bike to make it go as fast as possible. 

It’s all the above, working together in perfect harmony, that make the Empulse so special. It feels like the next evolutionary step of the motorcycle, full stop.

There’s not much more that I can say.  It’s going to take a while for me to really digest what all this means for motorcycling in general, or electric motorcycles, but it’s refreshing to step back and take a nice, clear look at what makes all this work, and why it’s been a lifelong obsession, in the words of one of the most rabid enthusiasts, as well as someone who has a pretty decent command of the language.

Now, the one thing that remains a question is the acceleration issue with the Zero.  Why, at similar specs, is the Zero such a dog off the line?  There’s been a lot of discussion about that over the last few years, but early on, Zero limited the off-the-line performance, possibly to deliver a little safer, albeit less thrilling, and more economical ride.  Here’s a thread by the legendary doctorbass about “pimping” the Zero, on Endless Sphere.  The wisdom of de-tuning the acceleration of a sport bike eludes me, but, whatever.  The unsubstantiated numbers I’ve read online are that the Zero accelerates at around 0-60 in 10 seconds or so.  The Empulse is rumored to be closer to 4sec.  A huge, huge difference, and the difference between a scooter and a real motorcycle.  So, if you love the Zero and just want a better ride, you can always hack, or swap, the controller.

…but it sounds like there’s more to it than that, alone.

Thanks, Wes, for taking the time to answer my questions, and thanks for the great work.

Every single blessed time I take this bike somewhere on the trailer, it rains.

I don’t really baby my motorcycles, but an open lipo pack with a few healthy kwhs workin’ isn’t something I really want to get drenched, plus, there’s road dirt.  So, the choices are either an enclosed trailer that hides the bike or some sort of cover that’s able to withstand wind at highway speeds.  I found this material – scrim vinyl – that they use for banners and signs, and the stuff is perfect.  It’s a weight of either 10oz or 13oz – think heavier than that blue-tarp stuff you buy at Home Doopey – and, oh, by the way?  You can print on it.

Here’s my first stab at a pattern:

Yeah, I was goofing around with a faded-back image of the bike in spots to see how it looked, and also to give a bit of a tease as to what was underneath the cover.  Shockingly, it actually works.  It’s a really amusing illusion…  My sponsors are going to love having another billboard to put their logos up on, too.

Round Two is to have the rear open, with elastic straps to hold it tight, and gussets around the bars.  (You have to keep the bars open so you can strap the bike down to the trailer via the triple clamps.)  It’s as slim as it can be, with no extra material to flap around, and the fit to the bike is perfect.

Just call me Betsy Frikkin Ross.

 

 

Zero ZF9 vs Brammo Empulse R: Spec Battle

So, OK. It looks like the Empulse has some real specs. Time for a spec battle. Here you go, from the spec pages on the respective bikes except where noted:


Zero ZF9 Brammo Empulse R
Range
City (EPA UDDS) 114 miles (183 km) 121 miles (195 km)
Highway (commuting, 70mph) 63 miles (101 km) 56 miles (90 km)
Motor
Type High efficiency, double-stator axial flux permanent magnet, brushless motor with integrated forced air cooling. 42 ft-lb @ 3800 rpm. Permanent Magnet AC (PMAC) – Water Cooled 40kW, @ 8,200 rpm (54 hp), 63Nm (46.5 foot pounds)
Controller High efficiency, 420 amp, 3-phase brushless controller with re-generative deceleration

(Sevcon Gen4, Size 4, 3-Phase controller)

Sevcon Gen 4
Top speed (max) 88 mph (142 km/h) 100 + mph (160 + km/h)
Power System
Type Z-Force™ patented Li-Ion intelligent power pack Brammo Power™ BPM15/90 Lithium-Ion ( NCM Chemistry)
Maximum capacity 9.0 kWh 10.2 kWh (max)
Nominal capacity 7.9 kWh 9.31 kWh (nominal)
Estimated pack life to 80% (city) 308,000 miles (495,000 km) 1,500 cycles to 80% capacity (100% DOD) (ED NOTE: @ an average range of 70mi, that’s about 100,000 miles.)
Charger type 1kW, integrated
Charge time (standard) 9.0 hours (100% charged) / 8.0 hours (95% charged)  Level I maximum charging time: 8 Hours. (0 – 99% SOC, no cell imbalances)
Quick 2x charger time (accessory) 4.9 hours (100% charged) / 4.0 hours (95% charged) Level II maximum charging time: 3.5 Hours. (0 – 99% SOC, no cell imbalances)
Quick 3x charger time (accessory) 3.1 hours (100% charged) / 2.7 hours (95% charged) Every 10 minutes of Level II charging adds up to 5 miles of range
Quick 4x charger time (accessory) 2.4 hours (100% charged) / 2.0 hours (95% charged)
Drivetrain
Transmission Clutchless one speed IET 6 speed gearbox with multi-plate, hydraulic activated wet clutch
Final drive 132T / 28T, Poly Chain® GT® Carbon™ belt Direct Chain Drive (14/48) 520 O-ring chain
Chassis / Suspension / Brakes
Front suspension 38mm inverted forks with adjustable compression and rebound damping Fully Adjustable 43mm Marzocchi Forks
Rear suspension Direct-link shock with adjustable spring preload, compression and rebound damping Fully Adjustable Sachs Shock
Front brakes 2 piston hydraulic, 310×4 mm floating disc Dual 310mm Brembo floating disk with twin four piston Hydraulic Brembo Brake Calipers, Radial Mount.
Rear brakes 1 piston hydraulic, 220×4 mm disc Brembo single disk with dual piston Hydraulic Brembo Brake Caliper
Regenerative Braking Yes  Yes
Front tire 110/70-17 120/70-17 AVON AV79
Rear tire 130/70-17 180/55-17 AVON AV80
Front wheel 3.00×17 17”x 3.5” Marchesini
Rear wheel 3.50×17 17” x 5.5” Marchesini
Dimensions
Wheel base 56.6 inches (1438 mm) 58.0” 147.32 cm
Seat height (standard) 32.8 inches (832 mm) 31.5” 80.0 cm
Rake 23.1 degrees 24°
Trail 3.0 inches (76 mm) 3.8″
Curb weight 341 pounds (155 kg) 470lbs. / 213kg
Carrying capacity 340 pounds (154 kg) Cargo Capacity 365 lbs. / 165.6 kg (805 lbs. / 365.1 kg total combined motorcycle, rider, passenger and cargo)
Pricing
Starting MSRP $13,995.00 $18,995.00

The specification page for the Zero is here.  The Brammo Empulse page is here.

* I’m pretty sure they’re using a fairly stock Motenergy ME 0913 motor. At  0.15 Nm/amp, and 420A maximum, you have 63Nm

Brammo Empulse Road Test (HFL)

“The Empulse is simply a more pure experience than any gasoline-powered bike could ever be.”

Read the story here.

Apparently, bitch found out what I’ve been saying all along…  an electric motorcycle with decent power is like nothing else I’ve ever ridden in 40 years of motorcycling.  Read some more:

Brammo’s able to achieve some pretty extreme mass centralization with its electric drivetrain, squishing the batteries between the frame rails into a tight bundle around the ideal center of gravity. The motor and transmission are very small, contributing to that centralization.

You know mass centralization is good because of Honda’s significant push to inform people that the CBR range is a little bit like its MotoGP bike. But Brammo is able to achieve something even HRC isn’t, totally eliminating reciprocal inertia and the noise, vibration and harshness that comes with ICE propulsion. All those pistons whirring up and down at insanely high speeds have a way of blunting a bike’s turning speed. All those tiny explosions and their subsequent noise and vibration have a way of getting in the way of communication from the tires, suspension and brakes. Electric motorcycles: taking 100 years of motorcycle development to the next level.

…and finally: “Electric motorcycles: finally here.”

Congratulations to Brammo for building a motorcycle that the skeptics can’t ignore…  that changes some minds.  Congratulations for, in spite of all the production issues and internet blather, finally delivers a game changer.  Whatever the future of Brammo, Zero, and the electric motorcycle industry in general, remember this day.  This is the day that motorcycling changed for not just a handful of fanatics, but for everyone who rides a motorcycle.

Hell for Leather is a subscription site.  They leave stories up for a short time, then lock them down.  Don’t be a chump.  If it’s locked down, then buy a frikkin subscription, it’s well worth it, and a fraction of the cost of your porn.  (Update: see comment below, thank you sir!)

Thanks to “Guy”, I stand corrected.  Well.  Sort of.  Lipo is kind of a general term…  The Empulse cell I showed in my previous post is what is commonly called lipo.  It is, according to their specs, NCM, or nickel-cobalt-manganese chemistry.   Read more at SAE.org, but the chemistry represents one-third the mass and half the volume of an array of current lithium-ion phosphate cells in a pack of equivalent power.  According to Battery University, they  are “Most safe; lower capacity than Li-cobalt but high specific power and long life.”

Lipo is kind of a catch-all term that can include a bunch of different chemistries.  From Battery U, again, “Li-polymer can be built on many systems, such as Li-cobalt, NMC, Li-phosphate and Li-manganese. For this reason, Li-polymer is not considered a unique battery chemistry. Most Li-polymer packs for the consumer market are based on Li-cobalt”.  (Read here, “RC lipo”.) FYI, the older Li-cobalt?  Them are the things that blow up and stuff.

They also “packaged the pouch-type NCM-Li cells in modular building blocks that can support various thermal management options (air or liquid cooling) and also enable Axeon to rapidly produce prototypes of the technology for other vehicle types, which would significantly reduce development lead times.”.  They obviously have been reading my posts.

Brammo Empulse Road Test Tease: LIPO

Want to see about as far under the hood as you can see, behind the 100mph/100mile range of the Brammo Empulse?  Courtesy of the boyz at Hell for Leather*, feast your eyes.  You’re looking at a 8ah lipo cell that makes up the Brammo Power pack.

Yes bitches.  A whole bunch of these go into this:

…which goes into this:

So uh, yeah.  Probably a little more agressive QA than the RC lipo, but we’re talking the same chemistry.  One can only assume they’re satisfied with the various concerns…  safety, cycle life, reliability.  Like that.

Want to see more?  Check out the whole review on Hell for Leather, tomorrow.  Road test.  Photos.  Battery prOn.

You should also follow the Hell for Leather Facebook Page to keep up.

*a Proper bunch of journalists.

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