First size test for the bike wheel hub battery I'm designing - which I'm going to tongue in cheek refer to as the Tri-Force due to its three pieces - is a success. There's enough clearance between the spokes to get the pieces in and out.
The plan is to attach them with straps so I can maneuver them, then secure them at the hinges. Depending on the angles I may be able to skip the hinges.
[#]bikeTooter #3dprinting #diy
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I'm enjoying the challenges of designing for the "Tri-Force" bike wheel hub battery.
Since the lights will be remote controlled, I need to fit a receiver into the plug; I don't want in the battery because that may complicate charging.
So, I have to fit a 11x24x8mm chip, and the eight wires involved (two from the battery, two from the lights, four from the chip) all into as small a form factor as possible, all in the space between two spokes forming a wedge.
Fun!
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After five and a half hours, the first full scale test is ready. And there are notes.
To accommodate using battery clips instead of a modeled holder and a nickel strip tail, I had to increase the thickness to 36mm. Now it barely fits between the spokes.
But, I was able to get in on and off with two of the three hinge pins in, which is good.
When the clips arrive on Tuesday I'll iterate on the thickness - I may have to use 21700 cells instead of 26650 cells.
[#]bikeTooter #3dprinting #diy
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@yantor3d OOOH so batteries stay inside the hub?
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@chengdulittlea Yes, they do! Around the hub, to be precise. Each chamber of the ring will have one 21700 cell - wired in series with a BMS it yields a 12V 5,000 mAh rechargeable battery.
And don't worry - the final product will be fully enclosed. This was a test print to check the fit, so I skipped the side walls to save a few grams of filament.
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@yantor3d So is the idea that you have 1 wheel that contains battery and another wheel that has a hub motor and you won't need a thick frame for putting batteries?
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@chengdulittlea Not quite. This is to power LED strips on the wheel rims to help with being visible / conspicuous when riding at night, in the rain, during the long Portland winter.
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@yantor3d awww that's neat! Looking forward to see the outcome :D
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@chengdulittlea I've a few more iterations to go before I print the final parts, and need to order some more pieces. If all goes well I may finish it by the end of the year!
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