10 April 2016

2Spec Design have solved our Gearbox conundrum

I'm delighted to welcome Chris Hughes from 2Spec Design to our growing band of sponsors. Chris is a highly experienced transmission designer and answered my plea for help to design a transmission that would handle the awesome torque and power of the Fast Charge bike.

Chris has been working on the design of the gearbox, alongside GEMMC on the motor development and Rob on the chassis design. We've had a number of iterations of the design - mainly because the constraints on assembly and overall packaging in the chassis are so tight. I'm delighted to say that we are pretty close to resolving it now.

For the technical-minded it's basically a single speed reduction gearbox, using two sets of 31:59 gears to give an overall ratio of 3.81:1. This reduces the motor's peak speed from 22,000 rpm down to 5,750 rpm, after which a standard motorcycle chain/sprockets set gives us 2.5:1 reduction to the rear-wheel rpm of 2,300.


Gearbox assembly. Image (C) Copyright 2spec design Ltd 2016. All Rights Reserved

Gearbox assembly. Image (C) Copyright 2spec design Ltd 2016. All Rights Reserved


Gearbox internal assembly. Image (C) Copyright 2spec design Ltd 2016. All Rights Reserved

As with everything else on the bike, we can't afford to over-engineer "just in case" as we need to keep weight and inertia as low as we can possibly. This gearbox has been designed for a life of about 15 hours - plenty when it's only working hard for a few seconds at a time, but somewhat different to Chris's more usual demands of 250,000+ miles for an automotive transmission!

We've just got to get it made now - and with no budget earmarked for it (it was a late addition to the specification) we're struggling... Can you help? Please get in touch with Phil Edwards on 01825 761890 if you can; I'd love to hear from you.

++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++

Keep watching the blog for more news, or click the links to Like Us on Facebook and Follow us on Twitter

You can also keep up to date by registering for the newsletter, or joining the supporters club; details are HERE. Sponsors still being sought.

If you'd like to join us on this extraordinary journey and share the publicity get in touch with Phil on 01825 761890

Inspiring the next generation of scientists and engineers at www.FastCharge.org

Special Screws from TR Fastenings

In our quest to keep weight to a minimum our long-term supporters from TR Fastenings have kindly provided us with a big box of specially made aluminium M6 screws. These will be used to secure the busbars.

The weight that we save per screw is tiny, but when you need nearly 1,500 of them it adds us to a few kg's - a very valuable saving.

1,500 special aluminium M6x11 countersunk pozi-head screws we'll be using
Image (C) Weald Technology Ltd 2016. All Rights Reserved

A selection of the 1,500 special aluminium M6x11 countersunk pozi-head screws we'll be using
Image (C) Weald Technology Ltd 2016. All Rights Reserved 
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++

Keep watching the blog for more news, or click the links to Like Us on Facebook and Follow us on Twitter

You can also keep up to date by registering for the newsletter, or joining the supporters club; details are HERE. Sponsors still being sought. If you'd like to join us on this extraordinary journey and share the publicity get in touch with Phil on 01825 761890

Inspiring the next generation of scientists and engineers at www.FastCharge.org

NE Plastics manufacture the Honeycomb boards

It was exciting when I visited NE Plastics at their factory in Sidcup, Kent, yesterday to see the first of the PE300 polyethylene boards being manufactured. We are using these to hold the capacitors in place - you can see the capacitors held in them in this recent CAD model of the finished pack.

Small mock-up panel used to test capacitor mounting and busbar assembly
Image (C) Copyright Lyra Electronics Ltd 2016. All Rights Reserved

CAD model of complete pack. the PE300 'honeycomb' panels are used to support the capacitors
Image (C) Copyright Lyra Electronics Ltd 2016. All Rights Reserved

We are also making up a dummy pack, without the capacitors fitted, for use when fabricating the chassis, so the pack just slots straight into place when it's time to assemble the bike. For that purpose we have had a set of PE300 boards cut that only have the holes for the tie-bars that you can see at top and bottom of the pack.

NE Plastics CNC Router
Image (C) Copyright Weald Technology Ltd 2016. All Rights Reserved


Profiling one of the dummy boards
Image (C) Copyright Weald Technology Ltd 2016. All Rights Reserved

Board profile completed
Image (C) Copyright Weald Technology Ltd 2016. All Rights Reserved
A 10mm board having a series of 60mm holes routed for locating the capacitors
Image (C) Copyright Weald Technology Ltd 2016. All Rights Reserved




Video (C) Copyright Weald Technology Ltd 2016. All Rights Reserved


+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++

Keep watching the blog for more news, or click the links to Like Us on Facebook and Follow us on Twitter

You can also keep up to date by registering for the newsletter, or joining the supporters club; details are HERE. Sponsors still being sought. If you'd like to join us on this extraordinary journey and share the publicity get in touch with Phil on 01825 761890

Inspiring the next generation of scientists and engineers at www.FastCharge.org