A Super-Brain For An E-bike

March 7, 2020 by Bryan Cockfield 12 Comments

There’s no better way of improving a project than logging data to make informed decisions on future improvements. When it came to [Brian]’s latest project, an electric bike, he wanted to get as much data as he could from the time he turned it on until the time he was finished riding. He turned to a custom pyBoard-based device (and wrote it up on Hackaday.io), but made it stackable in order to get as much information from his bike as possible.

This isn’t so much an ebike project as it is about a microcontroller platform that can be used as a general purpose device. All of the bike’s controls flow through this device as a logic layer, so everything that can possibly be logged is logged, including the status of the motor and battery at any given moment. This could be used for virtually any project, and the modular nature means that you could scale it up or down based on your specific needs. The device is based on an ARM microcontroller so it has plenty of power, too.

While the microcontroller part is exceptionally useful ([Brian] talks about some of its other uses here and gives us even more data on his personal webpage), we shouldn’t miss the incredible bike that [Brian] built either. It has a 3 kW rear hub motor and can reach speeds of around 60 mph. While we let the commenters below hash out the classic argument of “bicycle vs. motorcyle” we’ll be checking out some electric vehicles that are neither.

Generate Power As You Ride With A Bicycle Planar Alternator

March 2, 2020 by Jenny List 21 Comments

For most riders, bicycle lighting consists of an array of LED lamps and flashing gizmos, usually powered by lithium-ion batteries, or coin cells for the smaller ones. Some people though prefer to dispense with batteries and generate their own power, and that’s what [Thomas D] has done by fitting his bike with an alternator. But this is no off the shelf unit that rubs the tire or sits in a wheel hub. Instead, he’s built his own planar alternator that attaches to the spokes.

The design is inspired by those used in some wind generators, a central disk holding a set of planar coils sits between two rotating disks holding magnets. The stator holding the coils is made from laser-cut acrylic, and the rotors holding the magnets are sheet steel. One rotor is attached to the rear wheel spokes of the bicycle in close proximity to the stator which is attached to the rear frame. The second rotor sits on the other side of the stator while attached to the first rotor by its edge.

The coils are wired as two parallel groups in series in a ring with a single-phase output that feeds a rectifier and DC to DC converter. It would be interesting to see the effect of the same alternator with different winding arrangements or multiple phases.

This is the first time we’ve seen one of these on a bicycle, but this type of alternator has appeared here in more than one wind generator.

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An Open Source Ebike

February 23, 2020 by Bryan Cockfield 47 Comments

In the ebike world, there are two paths. The first is a homemade kit bike with motors and controllers from China. The second is a prebuilt bike from a manufacturer like Giant, with motors and controllers from China, which will be half as fast and cost three times as much. The choice is obvious, and there are other benefits to taking the first path as well, such as using this equipment which now has an open source firmware option.

The Tong Sheng TSDZ2 drive is popular in the ebike world because it’s an affordable kit motor which has a pedal-assist mode using torque sensors, resulting in a more polished experience. In contrast, other popular kit motors tend to rely on less expensive cadence sensors which are not as smooth or intuitive. This new open source firmware for the TSDZ2 further improves on the ride by improving the motor responsiveness, improving battery efficiency, and opening up the ability to use any of a number of color displays. (More information is available on a separate Wiki.)

If you have a TSDZ2-based ebike it might be time to break out the laptop and get to work installing this firmware. If you’re behind the times and still haven’t figured out that ebikes are one of the best ways to travel, here is the proof you need.

Thanks to [coaxial] for the tip! Photo via Reddit user [PippyLongSausage].

The Ruscombe Gentleman’s Steam Bicycle

January 8, 2020 by Danie Conradie 16 Comments

Cycling for health and transportation might seem like a good idea, but it unfortunately has the nasty side effect of making you tired. To ease the suffering, many have turned to electric bicycles. But what if you want to really stand out from the crowd? Well then you should look to [Mark Drake] for inspiration, the creator of the beautifully engineered Ruscombe Gentleman’s Steam Bicycle.

[Mark] wanted to create a steam powered bicycle that’s actually usable, instead of just an awkward novelty. To achieve this he made extensive use of modern tech like spreadsheets to model the steam cycle, and CAD for the mechanical design. The engineering design that went into the project really shows in level of refinement of the end product, which is able to comfortably reach 15 mph. Watch the video after the break to see it in action and get all the details.

Petrol is used a fuel source, which is forced to the vaporising burner via air pressure. The fuel is heated by the burner itself to form a vapour before entering the combustion chamber and igniting. The steam generator is a hybrid design, using both mono tube steam generator coils and a small fire tube boiler. This produces superheated steam at over 300 °C, which [Mark] says is key to the bike’s performance. Mineral oil can’t handle the high temperature, so modern synthetic oil is used for lubrication. The steam generator is so well-built that [Mark] managed to get is certified to industrial standards. For safety, it features both a pressure release valve, and a system that automatically shuts of the fuel supply when the steam exceeds a certain pressure. 130 W of power is provided to the wheels by a single cylinder slide valve engine via modern toothed belt. This also drives the air pump to keep the fuel system pressurised, and an adjustable water pump to feed the boiler. Continue reading “The Ruscombe Gentleman’s Steam Bicycle” →

Vintage Bike Gets Briggs And Stratton Power

November 20, 2019 by Lewin Day 18 Comments

eBay made the process of motorizing a bicycle popular, with cheap engines from China combined with a handful of parts to lace everything together. If your tastes are a little more vintage however, [Oliver]’s build might be more your speed.

Starting with a real Briggs and Stratton liberated from an old rotary tiller, this engine has legitimate vintage credentials. Looking resplendent in brown, it’s paired with a bike in a similar shade from yesteryear. Drive from the engine is transferred by belt to a jackshaft, which then sends power through a chain to the rear wheel. The belt tensioner serves as a rudimentary clutch, allowing the engine to be disconnected from the drivetrain when disengaged.

The retro components, combined with an appropriate color scheme, make this a wonderful cruiser that oozes style. While it’s probably not suited for downtown commuting due to its lack of a real clutch and noise, it would make a great ride for taking in some country roads on a sunny day. We’ve seen similarly styled e-bikes, too. Video after the break.

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Bicycle Transforms Mid-Ride

November 13, 2019 by Bryan Cockfield 9 Comments

For those of us who were children in the late 80s and early 90s, we may have dreamed of one day owning a gigantic tractor trailer that could transform into a colossal fighting robot. Or of simply having a toy that could approximate this change from one form into another. As adults, though, we have come to realize that this is wishful thinking. That is, unless we decide to build this transforming bicycle.

What starts out as a slightly unusual-looking low rider-style bike effortlessly turns into a tall bike by means of a gas cylinder fixed to the bike’s rear triangle. The bike started out as a full suspension mountain bike, but the rear spring was removed to make room for this cylinder. The pivoting action of the rear triangle in a mountain bike is the key design element here: it allows the frame to change shape easily, in this situation when pushed by the cylinder. Adding some longer forks in the front and a coat of paint finishes the build.

This bike was entered in the Make It Move contest on Instrucables, and has gotten some pretty wide recognition so far. It’s a unique bicycle to be sure, and we’ve seen a few. From Russian offroad electric utility bicycles to bicycles that keep drivers from speeding down roads, there have been lots of interesting bike-based builds.

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Steam Bike Rocks It Old-School

September 20, 2019 by Lewin Day 22 Comments

Petrol engines dominate the world of the automobile, while electric propulsion races to take an ever larger market share. Despite this, some still hold a flame for steam power. Such aficionados would hold this build in high regard, from the recent past of 2014.

The bike is of a recumbent design, featuring a relaxed riding position well suited to the sophisticated nature of a steam-powered vehicle. Sporting a wooden frame, the build carries a strong steampunk aesthetic. The flash boiler packs 100 feet of copper pipe, and there’s an electric pump and controller to handle water delivery from the stylish brass tank. The setup is capable of producing steam within 30 seconds of startup. Motive power is courtesy of a 1.5 inch bore single-cylinder steam engine, connected to the rear wheel via a belt drive.

There’s something intoxicating about the sounds and smells of a working steam engine, though the threat of catastrophic burns does temper the excitement just a touch. Steam power isn’t going away any time soon – and it’s not just limited to transport applications, either. Video after the break.

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