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Refining Things

A project log for Light Electric Utility Vehicle

A rugged low-cost solar electric utility vehicle platform for the developing world

chris-lowChris Low 05/23/2015 at 15:340 Comments

While I have generally been pretty happy with the vehicle so far, there are a number of areas I would like to improve on. In my mind the current vehicle is more of a test bed to see what will work and what won't for the next version. I already have a pretty significant redesign done on the computer, but I would like to keep testing the current version to find more weak points. One area I had to change was the motor mounts. While they fit nicely in the original frame, mounting them upside-down as I originally had them put too much flex in the drivetrain, and caused them to slip. Instead I have mounted them on top of the frame in a way that allows me to tension them by a bolt. See photos.

This view shows the connection to the wheel. Because of the built in planetary gearbox on the motor I can eliminate multi-stage gear reduction which greatly simplifies things.

Amazing how well it works for the moment considering how few components there are.

Put on a cover/place where the seats will mount. I am hoping that I can eventually put in a shelf so that this will also act as a locking toolbox.

The lid flips up from two hinges on the back.

Another issue I am having is a bit more serious as I am hitting the current limit for the controller which is 60a per side continuous and 120a peak. Admittedly I am doing some torture testing as I am hitting this while trying to drive over big piles of loose sand, but it will continue to be an issue so I am looking at other options. The sabertooth 2x60 has built in over-current protection so I get a series of jolts when I am pulling between the 60a continuous and 120a 1 second peak. I think I need to find another controller. Which leads me to my question for everyone.

Does anyone have any experience with the OSMC open source motor controller? At 160a continuous and 300a peak it looks good on paper, but I feel like it is thermally questionable. Any newer designs out there with similar specs?

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