A little bit about my 2008 YZ250F Electric Conversion

#21
I personal, would not go with the Two controller Split stator setup for a dirt bike. But I would like to see it in action.

As was stated above by Dain_SSE, If you can get your hands on a Sevcon Gen4 size 6 and the IXXAT and the license I would start there.
Slightly smaller than the Kelly and will fit into the space you have, just fine.

Since I last sent a personal email to you, I spent another hour with the engineer on the programming the Gen4. It is Significantly better on
the low end and have plenty of top end as well and only went from a 50 to 52 rear and stayed with a 13 front sprocket.
We changed things to levels I have been very leery of doing as I didn't want to brick the controller. It is finicky. Still have not been able to
get the Hall Throttle to work with this controller, but the over all performance is better.

I am testing the Curtis Controllers we had custom made for these type motors. Although the total Amp rating is 450
I believe this is a solid 450 plus for short bursts. It is smaller and lighter than the Kelly or Sevcon, but the cost will be
around $1300. I think these are a better controller for the abuse they will be going through, and Curtis has been much
better to work with so far. Just waiting for the motor to be returned from the Dyno test.

I will let you all know how it compares.
www.xemx1.com
Mark
 

DonCox

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#25
Yea Phillip, you wheelied away from him and me. It was very clear that you and the ALTA were faster. And @Mark911, I don't know which is better, DTC (Direct Torque Control) or FOC (Field Oriented Control), I think the DTC is supposed to be noisier. I notice that when an ALTA moves away from me, I can hear the controller, and I can't on mine. What is the ALTA using? I sure would like to have the smoothness of the ALTA thru the powerband. Does anyone have the schematic for the ALTA controller. Would it work in the 100V range? I built my own controllers in the beginning, and learned a lot. 10KHZ is loud, and I couldn't get the IGBTs to last. It squealed like a pig and didn't go far. Maybe I don't need the schematic. Just buy one of the working controllers. Mark911, your new bike rips from what I hear. Sevcon 72V 550A . Are you going to try the BAC8000? I would be really curious on that. You want a test bed, I'll bring mine over and it would mount easily. That would knock off 5lbs off my bike. Bob in Yorba Linda should have his BAC8000 back from ASI soon, and on a very similar motor, ME1304, so we should know soon how that works.
 

Mark911

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#26
I've got a BAC8000 just sitting right now. I'm planning on running it in the Yamaha as soon as I complete all my Sevcon testing. The Sevcon has so many bells and whistles it's taking forever to try all the various combinations and assess the performance both on the dyno and on the track. I'm closing in on the parameters that make the biggest difference in the "smoothness" of the power delivery but it's still a compromise between good throttle response and excess wheelspin.

The ASI is pretty simple by comparison, but it doesn't accept sin/cosin encoders so I need to adapt an UVW to my motor first.

The biggest difference with the Sevcon is whether the motor is IPM or SM. They both have their own unique set of algorithms built into the PMAC controller firmware, some settings work for one and not the other. The Hawk motors (like mine) are all SM.

I've attached my latest tune with the Alta graph (alta red, MSC tan). Note: all the actual dyno numbers are not shown intentionally. When Matt Cerami mentioned in the video that the Alta felt stronger down low but the Yamaha pulled longer he was spot on. The 300plus Alta volts and subsequent lower voltage sag results in a significant torque advantage below mid speed. After mid speed the Alta begins to fade fast as the Yamaha continues to build and pull. By 3/4 speed the Yamaha has the advantage which continues to widen. Peak HP is pretty close (at least compared to the torque), but the Alta has a large "area under the curve" advantage. I haven't track tested this tune yet but plan to in the next couple days. The main issues with past tunes (more powerful/torquey low end) was the initial "hit" off throttle was simply too brutal/uncontrollable making getting on the gas (electrons?) hard in a truly scary way. Hopefully, the slower ramping will make the bike easier, although less exciting, to ride fast.

altayama.jpg
 

Mark911

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#28
No, it's a "name brand" inertial dyno with DIY upgraded software from a company in Australia. On the drum the Alta will almost tear the knobbies off at lower speeds, but it does fall off. Surprisingly, it's not uncontrollable on the track as we all know. I think that's due to a good choice of both torque and rpm ramp rates. I think it might even be speed (mph) related, with higher ramping at higher speeds when traction isn't as much an issue.
 

riverin

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#31

Rashid510

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#32
TM4 TautronicTM | Dana TM4

Claims to supply the inverter to Zero motorcycles. Maybe the new SRS bikes? I think all the older models use sevcons...

Also to address my own curiosity, this was the only place i found selling the sevcon software (didn;t try Borg Warner directly though)
ThunderStruck Motors - Sevcon Gen4 Calibrators
SDS and XMX platform used Sevcon Gen4s...(size 4 on the FX and Size 6 on the SR/DSR)..Sevcon did a special Gen 4.5 controller for Zero so they could bridge between the next gen controller (slightly more powerful Mosfets) then Sevcon got bought by Borg Warner.

The SRF platform motor controllers started off being made by SME (Italian company) which got bought out by Dana and became part of the TM4 Line. You can try to get a controller from a Zero Dealer...but it will be preconfigured to a Zero...but its an option technically.
 

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