Kayak Power….  V2 in the water

Last night (after sunset) we were able to breach the harbor mouth under new power.

In the pics you can see the vintage Minn Kota that powered V1.  Tiny motor, tiny prop.  Next to that is a big upgrade courteously of a Masterguide bow mount.

(note:  I apologize for the pictures.  My Nexus 5X is finally giving up the ghost after a very hard life.  It was an excellent phone.)

Both of those motors are 12V rated…  but obviously the one on the right is capable of putting on a better performance.

We picked up a bow mount Masterguide (remote control steering and all) for $26 at the Fleamarket.  It had a bad steering gear box and trouble with the PCB board.

No problem…  all we wanted was the lower unit.  We disassembled it, along with the vintage Minn Kota, and put something new together.  The Minn Kota donated only the mounting hardware.  Control is handled by a 300A AXE controller.

This is a progress pic (of course that stuff needs to be ocean resistant…) but in it you can see the basic layout:

Battery:  6S 6P 35C Hobby King packs.  This works out to 22.2V @ 18Ah so capable of 20KW burst and almost 1kA.

Controller:  AXE 300A controller capable of 16V to 60V…  so Ebike battery compatible.

Throttle:  Zero pulldown 5K Magura.  Note that you need to configure this to run 5K to 0K (to avoid WOT on a disconnected throttle) and be sure to enable the interlock on startup (wont run until it sees 0% on the throttle).  Take your time with the Magura and make sure you get a clean 5Kohms to 0ohms…  they can be calibrated and many people change the output range to match a standard 1.2V to 4.2V hall throttle.

Wiring:  Coming out of the lower unit were 4 wires…  the heavy RED and BLACK are direct motor connections.  The Green and Blue can be ignored as they go to a mosfet pack that we wont be using.  (The AXE controller handles all our PWM needs)

We connectorized everything up with Anderson PP45’s in parallel (2P can handle 100A continuous into 10AWG) and SB120’s…  which are rated for 240A @ 600V.  Balance taps are paralleled at the cell level using MethTek parallel boards.  Currently there is no BMS in the system, we are working on that.

As a rule of thumb…  doubling voltage quadruples power.  In this case we doubled voltage and sized up the prop considerably…  leading to a huge performance increase.  The speed and acceleration is night and day.  We will grab some GoPro video some time this week.

V3 will be a Gen 4 Sevcon along with a 75-7…  but that adds all sorts of complexity that we are not in a position to tackle yet.  Prop angle, waterproofing, steering….


Sevcon Gen 4 Support

We are to the point where we can offer professional Sevcon Gen 4 support.

We have invested over a year into the minutia of this.  I dont want to make it sound complicated (because we can simplify it for you) but working with Sevcon hardware really does require professional support unless you are in a position to tool up, learn the tools, and invest the time.

We have an OEM relationship with Sevcon.

We have up to date licensed copies of DVT.

We can load DLD files.

We can read, modify, and write DCF files.

We can help you to transition your existing system from a Size 4 controller over to a Size 6 controller (for significant performance gains).

We can support you with Sin/Cos encoders, UVW encoders, wiring and pin mapping, basic tuning, and some Dyno tuning where appropriate.

We have a line of custom harnesses built to or above OEM Automotive spec that (in combination with a DCF tuned to your hardware set) can make for a turn-key setup.

We can support any existing Zero Motorcycles gear as well as any equipment purchased from http://motenergy.com/.  We are working on supporting other existing motors like those found at Joby, Jozztek, and others.

We would like to support Boating applications, Kart applications, custom Motorcycle and Enclosed medium weight EV applications.  We are even starting to support some E-Flight applications (tho those require a higher level or rigor to assure air safety).

Currently we are working under the umbrella of an OEM as we develop a new Power Systems branch.  Until that venture is funded this is somewhat grass roots.

Hourly consultation is available – either over the phone or email.  Email is suggested as it tends to be more productive.  If you can clearly state what you have, where you are at, and where you want to go…  we can make suggestions as to other OEM’s and niche shops we work with.

We can suggest parts for safety and reliability (like throttles with interlocks) and inform you as to what you will need if you want to support yourself… or we can steer you toward one of our turn-key options

The key tools are:

  • Recent version of DVT
  • Proper galvanically isolated CAN programming device (IXXAT or Clone)
  • Professional 2 step crimpers and pins for Sevcon 35pin connector
  • Appropriate hall sensor and means to calibrate to motor
  • Harnessing and matching DCF

If you are looking for a turn-key solution…  or just looking for some help mastering what you already have, we are available.

At the moment we are working on a custom version of the ClearView iterface that will alleviate the need for DVT and an IXXAT such that customers can collect data and make minor changes without having to loop us in.

Feel free to reach out to us in the Contacts section.

All due respect to those who came before us like Ryan Biffard of Zero Motorcycles, the team at Thunderstruck-EV for their work supporting Sevcon, Steve at Jozztek in the UK for his EV expertise, and all the others who helped get us to where we are at.

Respect also to the companies where I have worked that first introduced me to Sevcon gear in their products – namely Zero Motorcycles and Electric Movement.