Friday, 2 August 2013

First had experience with a C5 at Sinclair in the UK

From: http://www.eevblog.com/forum/blog/eevblog-501-sinclair-c5-electric-car-teardown-test-drive/30/

Re: EEVblog #501 - Sinclair C5 Electric Car Teardown & Test Drive
« Reply #37 on: Yesterday at 08:31:10 PM »
Oh man! That's made my day. Let me take you back... back... back...

I worked for Sinclair Research in the mid-80s as a snotty-nosed teenaged Z80 programmer. I joined the day the C5 launched and worked initially in Sinclair's London office (a tiny place with just Clive, his secretary, his father and me - it's a long story...). So I came out of work and there outside the office was the C5 that Clive had been driving at the launch event - widely covered on the telly.  But, nobody knew what to do with it - it was a Friday afternoon, it wouldn't fit through the doorway into the office and you couldn't just leave it there. So light, someone could have picked it up and walked away with it.

"I know!" I said. "I'll drive it home and look after it over the weekend!"

Clive looked dubious "Are you sure?" he said, "It's rush hour, it's London..."

"You've just been on the TV telling everyone how safe it is," I said (teenagers, eh?). "What can go wrong?"

"Errr... OK" he said. What else could he have done?

So I drove it from Chelsea to Chiswick through the London rush hour traffic. Got a lot of attention - after all, it'd had been on the TV all day - and it felt really good.

Until I got to Hammersmith, about three miles from the office and about two from home, when the battery ran out. The advertised range was not quite working out... peddling it (with no gearbox) all the way home was not nearly as much fun.

"Yes," said Clive on the Monday. "There may be some bugs to work out..." Can't remember how we got it back - I think by van.

Some more background on it: it was designed by a couple of chaps at Milton Hall, home of Sinclair Research's Metalab in Cambridge, in conjunction with various suppliers. The P. Newman who co-authored the Unofficial C5 document is Perran Newman, who became my boss at Sinclair after I moved to Cambridge; we worked together on a few projects, including the Pandora portable Spectrum (yet another story).

The "washing machine" motor was in fact a variant of one used for electric torpedoes. The ULA was a typical Sinclair component; the Ferranti ULA in the ZX81 was the first such in any consumer device, and Sinclair had a preference for them over other solutions. It was possible - although I never took part - to put two batteries in series and go very fast indeed, I think the unofficial record was 30 MPH, if you didn't do it for too long. Sinclair engineers were an eccentric bunch, and did things like go jousting in muddy fields in Citroen 2CVs.

But so much on it was just too pared back - the nylon gears that stripped, the batteries that were just too wimpy, those brakes... and, yeah, the British weather. There was a sort of cagoule which clipped around the front of the driving space, but that made you look even more like Davros than before.

Happy days.But it was a doomed project... now, the C10...

Wednesday, 31 July 2013

Dave from the EEVblog goes for a hoon in my Sinclair C5s

Yours truly messing around with C5s on EEVblog #501 – Sinclair C5 Electric Car Teardown & Test Drive


Tuesday, 2 July 2013

My first CAN bus project.

My first CAN bus project, controlling a TC Charger (Elcon) using CAN bus from an Arduino. I can dial up the voltage and current required, and display status flags of the charger isn't happy.

:-)

Now for a crash course in 3D modelling and 3D printing to make a nice enclosure.

It is the 417V version charger but thankfully can work down to 36V batteries. Here it is charging a pack  of 12S1P Headways.

Saturday, 1 June 2013

Riding a C5.


This is a quick ride on the streets. It runs well apart from a squeaky brake. That goes away after a while.

C5 final touches.

I applied the finishing touches to C5 #1.

Replaced front wheel with steel hub / aluminium rim wheel from council clean-up.






 New 55Ah Battery fits perfectly. You can see the original connector has been replaced with a modern Anderson plug.




Land Rover indicators fitted. A perfect fit. Almost identical. The part number is PRC7044  They are available from eBay







Monday, 27 May 2013

C5 #1 more or less finished.

I didn't have time on the weekend to make a test ride video, but here are a few poorly lit photos.

I got #1 going by pinching parts from #2. #2 will probably never go again due to a worn gearbox output pulley and a rough body. Hopefully #3 has enough parts to make another good one.

When you ride it there will be a few things to watch out for from a maintenance perspective. The rear wheel bolt and bearings in particular. 

The side stickers are a little knocked, but look OK.

#2 looks a bit sad now. For #1 I took the headlight lens & Instrument pod.

I replaced the front wheel with a steel / aluminium one from a kids bike from a council clean up, The original one was melted. I must take a picture of that.

#1 pictures. All nice and clean. Complete with new decals where needed. It still needs a front indicator lens. I am awaiting a Land Rover indicator pair. They should be almost identical. Fingers crossed.

After test riding last weekend the drive wheel bolt was loose and the brake wheel bearing loose. I will take it on a longer run (with tools in hand) for a final shake down.

I have received some old 55Ah UPS batteries for them. The first one I tried died after a few hundred meters. The second one is holding up well. As we didn't have any battery tops, the battery power is now provided by Anderson connectors and new 6mm^2 cable.







Tuesday, 30 April 2013

C5 drive components

Planetary gearbox output drive pulley:
- Diameter ~31mm
- 21 tooth

Axle Drive pulley:
- Diameter ~107mm
- 68 tooth
- One Way Bearing INA HFL 2026 Only $14.95. http://www.vxb.com/page/bearings/PROD/Kit8242

Drive Belt:
- Length = 400mm
- Width = 18mm
- Teeth = 80 tooth
- 5mm Pitch
- Megadyne Isoran 400 RPP5 http://www.megadyne.co.uk/files/Products%20Guide%20Catalog.pdf P22
- Locally - 400-T5 80 400.0 from http://www.naismith.com.au/catalogues/pulleys/metric.pdf

Final ratio = 21/68 = .308 or a 3.23 reduction.

Replacement Aluminium Pulleys from Naismith:
- Large = 60-T5-16
- Small = 20-T5-16F for similar final drive ratio.

Could use 25mm wide pulleys to allow for machining.

Motor Bearing - Both Ends: GMN 6201 http://www.gmnbt.com/deep-groove-bearings-selection-guide.htm
Planetary support bearing x2 (on drive end of motor shaft) GMN 607
Large output shaft bearing 61808

3 x Gearbox planet carrier shafts ~ 8mm

Bearings verified fron C5 yahoo group.
> > Hi Folks...
> >
> > Somewhere someone prolly needs this info..
> > Universal part numbers for the motor bearings.....
> >
> > Outer gearbox bearing: 61808 (I'd recommend a 61808-2RS cos it's
> sealed)
> >
> > Planetary carrier inner bearings: 607 (no need to worry about
> sealing on
> > these really)
> >
> > Armature main bearings: 6201 (once again I'd recommend the 6201-
> 2RS, though
> > Sincalir fitted the 6201-ZZ which is shielded but not sealed)..
> >
> > I've got a new set on order for my motor, and it's costin me a bit
> over 20
> > UKP for one 61808-2RS, and a pair of each 6201-2RS and 607....
> >
> > chrisc






Wednesday, 17 April 2013

Wire Sizing Guide

I got tired of Googleing this every time I needed it, so here is my version.

Gauge

Conductor Diameter

Conductor Diameter

Ohms per km

Maximum Current

Maximum Continuous Current

Cross Sectional Area

Will fit metric lug

Unit

Inches

mm

Ohms

Amps

Amps

mm2

mm2

0000 (4/0)

0.46

11.7

0.161

380

302

107

120

000 (3/0)

0.41

10.4

0.20

328

239

85

95

00 (2/0)

0.36

9.3

0.26

283

190

67.4

70

0 (1/0)

0.32

8.3

0.32

245

150

53.5

 

1

0.29

7.3

0.41

211

119

42.4

50

2

0.26

6.5

0.51

181

94

33.6

35

3

0.23

5.8

0.65

158

75

26.7

 

4

0.20

5.2

0.82

135

60

21.2

25

5

0.182

4.6

1.03

118

47

16.8

 

6

0.162

4.1

1.30

101

37

13.3

16

7

0.144

3.7

1.63

89

30

10.5

 

8

0.129

3.3

2.1

73

24

8.37

10

9

0.114

2.9

2.6

64

19.0

6.63

 

10

0.102

2.6

3.3

55

15.0

5.26

6

11

0.091

2.3

4.1

47

12.0

4.17

 

12

0.081

2.1

5.2

41

9.3

3.31

4

13

0.072

1.83

6.6

35

7.4

2.62

 

14

0.064

1.63

8.3

32

5.9

2.08

2.5

15

0.057

1.45

10.4

28

4.7

1.65

 

16

0.051

1.29

13.2

22

3.7

1.31

1.5

17

0.045

1.15

16.6

19

2.9

1.04

 

18

0.040

1.02

21

16

2.3

0.823

 

19

0.036

0.91

26

14

1.80

0.653

 

20

0.032

0.81

33

11

1.50

0.518

 

21

0.029

0.72

42

9

1.20

0.41

 

22

0.025

0.65

53

7

0.92

0.326

 

23

0.023

0.57

67

4.7

0.729

0.258

 

24

0.020

0.51

84

3.5

0.577

0.205

 

25

0.018

0.45

106

2.7

0.457

0.162

 

26

0.016

0.40

134

2.2

0.361

0.129

 

27

0.014

0.36

169

1.7

0.288

0.102

 

28

0.013

0.32

213

1.4

0.226

0.081

 

29

0.011

0.29

268

1.2

0.1820

0.0642

 

30

0.010

0.25

338

0.86

0.1420

0.0509

 

31

0.0089

0.23

427

0.7

0.1130

0.0404

 

32

0.0080

0.20

538

0.53

0.0910

0.032