Electric bike with 3D printed parts

Last crawled date: 1 year, 11 months ago

########################
Bike specs
########################
Top speed: 55 km/h (35 mph)*
Range: ~30km (18.64 miles)

* for higher speed change tire diameter (Dout) and/or pulley ratio (i) (see python script speedCalculation.py)
########################
Bike components
########################
Bike model: CUBE LTD CC 2007
Modifications{
Rear hub: Shimano FH-M756L XT Rear Disc Hub (36H Rear 6-Bolt Disc)
Rear tire: Michelin tire 26 x 2.1 (do NOT put wider it will rub against timing belt)
Brakes: Avid Elixir
}
########################
Electrical components
########################
Motor:
1 x Turnigy CA80 160kv Brushless Outrunner (50~80cc Eq)
https://hobbyking.com/en_us/turnigy-ca80-160kv-brushless-outrunner-50-80cc-eq.html?queryID=&objectID=14323&indexName=hbk_live_magento_en_us_products_hbk_price_stock_7_group_0_desc&___store=en_us

Speed controller:
1 x VESC 6 MkV
https://trampaboards.com/vesc-6-mkv--the-next-generation--benjamin-vedder-electronic-speed-controller-p-27517.html

Custom battery pack:
12s5p, 48V, (Li-ion)
60 x Sanyo NCR18650GA 3450Ah / 10A
//no link

BMS:
1 x Li-ion BMS 12s 48v(used only for charging - no BMS model)
DongGuan DALY Electronics Co., Ltd.
Discharge current: 15A
Charge current: 10A
With Balance, Common Port
https://de.aliexpress.com/item/1005001350181020.html?spm=a2g0o.productlist.0.0.418a6787ir8Je7&algo_pvid=e40eeac4-593e-49f5-857d-130f2025d21c&algo_expid=e40eeac4-593e-49f5-857d-130f2025d21c-39&btsid=0bb0623316125167009883371e1865&ws_ab_test=searchweb0_0,searchweb201602_,searchweb201603_

Charger:
Li-ion battery charger
Model: 48V3A
Input: AC220 50-60Hz
Output: 50.4V 3A
/no link (aliexpress)

E-bike Throttle/E-bicycle Thumb throttle:
https://de.aliexpress.com/item/32911587028.html?spm=a2g0s.9042311.0.0.676f4c4dxLJgva


########################
Belts and pulleys
########################
1 x HTD 5M Belt width 15mm, 1525mm, Teeth 305:
https://de.aliexpress.com/item/32834535091.html?spm=a2g0s.9042311.0.0.27424c4dbJY5lV

1 x HTD 5M Belt width 15mm, 270mm, Teeth 54:
https://de.aliexpress.com/item/32957926990.html?spm=a2g0s.9042311.0.0.676f4c4dxLJgva

2 x 30 Teeth HTD5M Synchronous Timing Pulley Inner Bore 8 mm for Width=15 mm:
https://de.aliexpress.com/item/32954345427.html?spm=a2g0s.9042311.0.0.27424c4dVwSOIH

1 x 10 Teeth HTD5M Synchronous Timing Pulley Inner Bore 8 mm for Width=15 mm:
https://de.aliexpress.com/item/32953832411.html?spm=a2g0s.9042311.0.0.27424c4dVwSOIH


########################
3D printed components
########################
Printer: Artillery Sidewinder x1
Material: PETG
Infill: 70%
Resolution: 0.2mm


########################
Other components for fastening and joining
########################
18 x High-Strength Steel Nylon-Insert Locknut
Class 10, Zinc Plated, M4 x 0.7 mm Thread, 5 mm High

18 x 18-8 Stainless Steel Socket Head Screw
M4 x 0.7 mm Thread, 45 mm Long

6 x M6 Furniture Joint Connector Bolt & Cap Nut Kit Use for Cot Bed Crib Bolts Hex Drive Socket Cap Bolts - Hex Socket Screws Head (60mm)
https://www.amazon.ca/Nickel-Plated-Furniture-Connector-Fixings/dp/B01LRGYS4O

2 x 18-8 Stainless Steel Socket Head Screws
M5 x 0.50 mm Thread, 20 mm Long

2 x Black-Oxide Alloy Steel Socket Head Screw
M5 x 0.8 mm Thread, 30 mm Long, Fully Threaded