Homemade Electric Buggy, Ep 7: Cooling System
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- Опубліковано 18 вер 2024
- Homemade Electric Buggy, Ep 7: Cooling System
In this video I install the cooling system for the electric motor in my homemade electric buggy. As some of you know, the battery is sized large enough to only require forced air cooling, but the motor requires liquid cooling (a glycol/water solution). To do that, I'm using an 8x12" radiator with a 12V, 7" fan from Derale Performance. The glycol solution will be circulated by a Flojet 12V general purpose pump with a flow rate up to 10 L/m. I made a reservoir/overflow container from 3" ABS pipe, an end cap for the bottom, a screw cap for the top and barbed fittings for connecting the heater hoses. I also incorporated a filter between the reservoir and pump to keep particulates out of the system. Links for all of the parts that I used can be found below with the exception of the ABS pipe and fittings and heater hoses. You can source those at a local home building supply store like Home Depot. Electricmotorsport.com also sells a complete kit with the pump, filter and radiator together to make things simple, but for a slightly higher price.
Radiator:
www.electricmo...
Pump & filter:
www.ebay.ca/it...
Complete kit:
www.electricmo...
Website: www.resystech.com
Support RST on Patreon or UA-cam and earn membership perks:
/ resystech
/ @jamesbiggar
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In this video I install the cooling system for the electric crosskart/buggy ME1616 motor. As some of you know, the battery is sized large enough for the motor to only require forced air cooling, but the motor requires liquid cooling (a glycol/water solution). To do that, I'm using an 8x12" radiator with a 12V, 7" fan from Derale Performance. The glycol solution will be circulated by a Flojet 12V general purpose pump with a flow rate up to 10 L/m. I made a reservoir/overflow container from 3" ABS pipe, an end cap for the bottom, a screw cap for the top and barbed fittings for connecting the heater hoses. I also incorporated a filter between the reservoir and pump to keep particulates out of the system. Links for all of the parts that I used can be found below with the exception of the ABS pipe and fittings and heater hoses. You can source those at a local home building supply store like Home Depot. Electricmotorsport.com also sells a complete kit with the pump, filter and radiator together to make things simple, but for a slightly higher price.
Radiator:
www.electricmotorsport.com/ev-parts/cooling/lck/radiator-with-1-2-inch-hose-barb-inlets-and-electric-fan.html
Pump & filter:
www.ebay.ca/itm/301739981256
Complete kit:
www.electricmotorsport.com/ev-parts/cooling/lck/liquid-cooling-kit-for-dlc-motors-and-controllers.html
Website: www.resystech.com
Support RST on Patreon or UA-cam and earn membership perks:
www.patreon.com/resystech
ua-cam.com/channels/trf6ZiE6hw3k77hGpnuQWg.htmljoin
Follow RST on Facebook:
facebook.com/RenewableSystemsTechnology
That 1/8 aluminum that you are bending, is that 5052?
No sir.
3003, I believe. Same grade used for roofing, siding, fuel tanks, etc. Excellent formability with reasonably good corrosion resistance, not quite as good as 5052 but it's all gonna be painted anyway.
Np.
@@JamesBiggar Thanks. I had mixed results with 6061. Actually, just bad. Separately, I have a similar build using a MOtenery motor and 8080IPS controller. That is a tricky controller with the sine wave sensor. Some people I see on UA-cam get persistent hall sensor errors (inja, aging wheels). Let me know if you run into troubles.
I have really enjoyed following along on this build. Something to consider on the coolant tank mount, this may be overkill, but covering the edges of the aluminum where it contacts the tank with some split vacuum hose would prevent the aluminum from digging into the plastic over time. I learned this lesson the hard way.
Thats going to be such a great vehicle, and you're going to have a blast riding it
that's impressing iam so excited to see this crosskart working
Its clear to me that you have thought through the issues, however what astounds me is the out of the box solutions you come up with. Very impressive James.
Thanks!
cannot wait to see the numbers, i haven't seen a water cooled electric motor before.
You have seen a Tesla, don't play dumb....
@@theecstatic9686 dude, tesla is using oil for cooling.
Mr. Biggar, you make it look simple. Nice!
That metal bending rig is amazing.
Thanks. Built it last summer. You can check out the video on my channel.
What an awesome looking vehicle is shaping up!
Good share, Thank you for introducing You have good skill.
Very neat work bro
Amazing build !
This is your hobby or business
Love from India 🇮🇳 ♥
Kind of both.
@@JamesBiggar That's how you know your doing things right!! Now if we could just get reliable cheap batteries, our creations could be very profitable!
Very Neat, great video
looking forward to the result...
First like first view bhai short out do next video mai ♥️♥️♥️
круто , без воды, все по делу нет трепа и все понятно !
Amazing amazing amazing!
Welcome back 🔙✌️ sir
You are as good as ever!)
Excellent project, I would like to see this great machine in action, I hope to see the videos of the tests soon off-road. Ah, and a question, ¿how does the vibration of the entire chassis caused by the road imperfections affect the batteries?
Looking good and can't wait to see you hooning around in the finished product. Wanted to ask about that vertical reservoir - if the only thing stopping it moving is that strap, isn't there a danger that the weight of fluid plus vibration will allow it to drop, and put pressure on the top valve as the strap presses against it?
Thanks. No. The hanger is mounted snuggly between the end caps - the reservoir can't move in any direction unless a tremendous load of some sort snaps that rugged bungee or bends the hanger. Vibration alone won't move it - a bungee that thick (1/2") can handle up to a 400 lb load. A 1/8" thick bungee can handle a 100 lb load. I did well just to get it hooked into place lol.
looking forward to new videos
Have you ever run into issues with too much heat? To me this seems like the hardest part of the build, to make sure you dont run too hot.
Only with the esc, which was a bit undersized because it was the largest I could find to match with the motor at the time (larger esc's are now available, and liquid cooling options to go with them). The battery and motor never get above 45C. LFP perform a bit different than NCM in that regard. They're not as energy dense but they can usually handle a lot of power without risking overheating whereas with NCM it's usually the opposite - nearly twice as much cap but they can't output as much power, and combined with the nature of the chemistry itself, pushing NCM to its limits will risk overheating. That's why I got away with passive cooling for this battery, but might need forced air cooling for the current e-moto which uses NCM because they're going to push 60C+ under normal conditions, but can't exceed 70C otherwise they could get damaged or damage the PETG enclosure that I'm making for it. Next to LTO, LFP is the safest chemistry. Far less likely to overheat with normal operation, and far less likely to cause a fire if they get damaged or short internally. The trade off is more weight/wh.
@@JamesBiggar Thanks for the detailed reply!
Have you considered making a parts list to sell on your website? Im definitely interested! Id love to hear your insights on different 'tiers' of this build with different motors / parts for different budgets like 'Medium / High / Ideal'.554tvt
If you have a radiator for each battery pack (not even sure how big) would that be enough cooling to get away with NCM batteries? Maybe its not even worth the hassle if they are more likely to flame up.
Interesante y exente diseño se ve profecional cuanto es el costo por producirlo saludos desde mexicali
Very cool how you let the heated brass make it's own threads in the pvc pipe. Saves some work tapping it. Did you run the fitting in again using silicon tape?
Interesting !!!
How am I just discovering this??
I am like this project. 🎉
Looks good 👍
Hey James why dont you put some sort of fenders for the rear tires and a spoiler will be nice too🤗...otherwise such a great project
A machine making machines🙄🥴 Can’t wait to see it dusting on roads😤🤘🏻
Wow .verry good bro.good job.
классная работа!)))
So good!
Hello and thank for your video.
I don't think that making thread in the plastic for brass fitting is a good idea for high temp liquid, because they have different thermal size-changing.
Hope this will work.
The fluid won't be any hotter than the water coming out of your kitchen tap, according to science. If it is, the system isn't working properly and the motor will burn up. As a building contractor and journeyman, I have 100% confidence in this - it's no different than a home plumbing system with a myriad of pipes and fittings of all different types of materials, from PEX, copper, brass, or ABS pipes to quick connect fittings made from plastic, metal and rubber that slip over said plastic and metal pipes to form tight, reliable seals in hot or cold distribution lines.
Well done. Are you building it off the cusp or did you make plans for the project? You are good at building this almost like you done it before. Haha! Great work!
Thanks! I created it in CAD first. Plans will be available after the test ride.
Can we see it on road in next part?
when you dune make a video to show how she do riding it ?
so much steel on that buggy - arent you worried its too heavy?
or is it a standard thing? just asking purely out of interest. love following this build
Yep, because it's a buggy, not a passenger vehicle. Tube chassis is a necessity for safety. Nope, not worried at all. Curb weight is ~850lb, on par with ICE powered pro crosskarts and rally-karts (700-900lb). That's saying something given that it'll be hauling around an extra 180lb of battery.
@@JamesBiggar cool
Beautiful!!! What are the Grey plastic pieces in the middle of 2 of the coolant lines? Thermostat valves?
Thanks! Just barbed unions to connect hoses together (some pieces weren't quite long enough for the job).
Hey, noob question... why wouldn't you cut the pattern and then bend? You seem to bend first and then cut... is it because you are limited by ur bending method, or is there sth else?
And, forgot to mention, ur series is amazing! Great inspiration
Thanks! Not every scenario needs a template - the steps you take to make the pattern could be used to make the actual piece instead. Bend it with extra material, then place it in position and mark where more material needs to be removed, cut then test the fit. We use this method when trimming and scribing in finish construction (carpentry). For example, I would cut a piece of window casing to a rough length (~1" longer than its expected total) and miter one end, then place it on the reveal mark on the window buildout with the miter lined up in the corner where it should be, and use a pencil to mark the exact position of the other miter on the opposite end - fool proof. Impossible to cut it too short unless a person cuts on the wrong side of their mark. Tape measures aren't the most precise tool for stuff like this.
@@JamesBiggar thank you, makes sense... :)
What temperature do you expect the water to get?
You migh need to consider a pressure relief valve.
It's an open system, a filtered vent tube will be located in the res cap. No pressure.
ah, great.
What are the expected temperatures of the water?
Will it get headlights?
I like it 😊
Unless the ABS you used is listed as UV resistant, you may want to paint it.
No need. Refer to the body panel video. It's located behind and under aluminum panels. The only light it will see is (somewhat) diffused indirect light through the mesh at the back of the kart on rare occasions.
...MAYBE, lol, it's the only circumstance I can imagine.
@@JamesBiggar Roger that. 🙂
It shouldn't be a problem regardless, really. Solid ABS pipe is actually an ideal choice for using outdoors - it's the same material that we use for plumbing roof vents (I'm a journeyman carpenter/contractor - plumbers don't like getting on roofs for some reason). It's used on the majority of residential and commercial roofs, in direct sunlight where I've seen roof surface temps climb as high as 80C. Code compliant. Cellular core ABS is the type that deteriorates due to UV exposure - it's not a good choice for outdoors.
Cell core ABS pipe has a hard/smooth inner and outer ABS skin with an ABS foam interior. End cuts look like a sponge. It's lighter and easier to cut.
👍👍👍❤❤💪💪💪
左手不捉拿做不至
Make an electric sports bike
I've already built 4 bikes lol. I'm done with bikes for a while.
Oo
I don't trust that tank support. It might slide down when it's full of fluid.
I do trust it, because I trust my judgement and foresight. As already mentioned, the hanger is mounted snuggly BETWEEN the end caps by a very strong 10"x1/2" thick bungee. A 1/2" bungee can support up to a 400 lb load. 12" of ABS pipe filled with antifreeze 'might' weigh ~10 lbs. I can barely stretch it enough with arm power to hook it in place. That reservoir isn't going anywhere.
@@JamesBiggar Thanks for the response. Keep up the good work, great build!