Hybrid Go-Kart

[EdtardisGreatest]

Hello Everyone,

I have started to build a Hybrid Go-kart with a 2000w Vevor motor and a 212cc Pro Point + electric starter. The idea is to use an Arduino microcontroller to control the gas engine and electric motor. I was thinking of replacing the default controller with a ND72260 and running it off a 52v battery (3p14s BAK 45D). For the hybrid stuff, I will put a hall sensor on the flywheel, and another on the electric motor axle for rpm detection. Since the electric motor doesn't have a clutch and is directly connected to the rear axle, one hall is enough for both. When in the hybrid mode, the gas engine starts up at 25km/h and slowly throttle up until the rpm of the gas engine matches the rpm + 100 of the electric motor, so when the centrifugal clutch engages, there's a little bump handing the power from one power source to the other (or so I hope). Gas engine throttle is controlled by servo, so is choke. For the electric engine, throttle is controlled by a DAC from 0.8v - 4.2v

Gear ratio info:

212cc: 12t to 40t
2000w: 9t to 40t

Since the 2000w motor is only running a little bit at the beginning, I think it can take the 80a max of the controller, so a little above 4kw of power. The tires are 13" so a top speed of about 70km/h.

I have never done this before........any thoughts?

 

[Kartorbust]

I don't recall anyone making a gas/electric hybrid kart on here. @Functional Artist is our local battery electric kart builder. I have a feeling keeping the electric motor constantly spinning even when it's not on and the kart is being moved by the gas engine, the motor will get more wear and could be potentially spun faster than it was intended for.

But the idea sounds good. I know up in Canada, Edison Motors sponsors a hybrid go kart event.

 

[EdtardisGreatest]

I don't recall anyone making a gas/electric hybrid kart on here. @Functional Artist is our local battery electric kart builder. I have a feeling keeping the electric motor constantly spinning even when it's not on and the kart is being moved by the gas engine, the motor will get more wear and could be potentially spun faster than it was intended for.

But the idea sounds good. I know up in Canada, Edison Motors sponsors a hybrid go kart event.

That's a good point, I'm thinking I might change the 40t to a 65t.... With the 40t, at full gas throttle the motor is still in its rated speed, but I think the gear ratio wont give me enough torque (the whole point of electric). The motor is rated for 5800rpm, 40t is 5600 and 65t is about 7400rpm.

I didn't know about the Edison thing, I'll look into it, Thanks.

 

[Whitetrashrocker]

Electric over gas golf carts use a similar function. Kinda.
Electric starter starts the cart moving and when the gas engine kicks in the starter switches modes and becomes a generator making for a charging system.
I wonder if you could implement a form of that.

 

[Kartorbust]

This is from Edison Motors themselves. Looks like some of the schools that took part also made videos too. Might be worth looking at those too.

 

[EdtardisGreatest]

Electric over gas golf carts use a similar function. Kinda.
Electric starter starts the cart moving and when the gas engine kicks in the starter switches modes and becomes a generator making for a charging system.
I wonder if you could implement a form of that.

I think the ND72260 controller can do regen (I hope), so that could definitely work, but I wonder if that might slow me down a bunch....Since the gas engine is only 212cc. I would also have to look into if the batteries can handle it.

 

[EdtardisGreatest]

This is from Edison Motors themselves. Looks like some of the schools that took part also made videos too. Might be worth looking at those too.

Looks like this is for just electric.....I guess after we finish the prototype I could send them a email. I don't know about actually participating since they are just so far away.

 

[Denny]

What happens when the electric motor can’t take the rpm that the gas engine can push?

 

[EdtardisGreatest]

What happens when the electric motor can’t take the rpm that the gas engine can push?

I imagine the electric engine can take 7800rpm since its rated at 5800rpm....I mean past 5800rpm, its no longer getting power, its just spinning. Do you think it would be a problem?

 

[Denny]

It’s up to the armature. But you may want to use a sprag to take it out of gear when the gas engine kicks in.

 

[Kartorbust]

It’s up to the armature. But you may want to use a sprag to take it out of gear when the gas engine kicks in.

I forget those exist, sprag gears and sprockets.

 

[panchothedog]

Are you doing this just to see if you can? Sort of like a mechanical challenge?
Or do you just like to complicate your life. More power to you. You've gotta very smart and skilled to pull this off. But other than to be able to say " I did it " doesn't seem to have much of a practical purpose.

 

[EdtardisGreatest]

Are you doing this just to see if you can? Sort of like a mechanical challenge?
Or do you just like to complicate your life. More power to you. You've gotta very smart and skilled to pull this off. But other than to be able to say " I did it " doesn't seem to have much of a practical purpose.

I think its a cool project. It is also a bit practical since I live in a city and a noisy gas engine isn't ideal, but this way I still have that option when I take it elsewhere.

 

[EdtardisGreatest]

Does anybody know where I can find a 52v battery that can do 80a< for under 400 cad? I was going to buy from 18650batterystore.com but they stopped shipping to Canada 2 days ago

 

[Whitetrashrocker]

Where's Functional Artist? He's the one to ask.

 

[Functional Artist]

Where's Functional Artist? He's the one to ask.

I've been sanding
...& sanding
...& sanding
...& "boy O boy" are my arms tired

This is an interesting concept
...but, IMO a hybrid go kart sounds kinda overly complicated

As you would need:
...(2) fuel systems (gas tank & battery pack)
...(2) motivators (ICE engine & electric motor)
...(2) drive trains (2 sets of sprockets & (2) chains)
...& trying to integrate...everything...into such a "small package"
...& then, trying to get everything to work together...IDK
&
Finding a 52V Lithium battery pack
...that can provide 80A
...isn't going to be cheap...either

As an 52V 80A BMS (Battery Management System)
...would probably cost more, than the batteries...themselves

 

[Whitetrashrocker]

I've been sanding
...& sanding
...& sanding
...

You can paint the fence next, and after that it's wax the car Daniel san.

 

[Functional Artist]

You can paint the fence next, and after that it's wax the car Daniel san.

That stuff is gonna have to wait
...as installing a steel roof on my house, "should (may) be" my next project

 

[EdtardisGreatest]

I've been sanding
...& sanding
...& sanding
...& "boy O boy" are my arms tired

This is an interesting concept
...but, IMO a hybrid go kart sounds kinda overly complicated

As you would need:
...(2) fuel systems (gas tank & battery pack)
...(2) motivators (ICE engine & electric motor)
...(2) drive trains (2 sets of sprockets & (2) chains)
...& trying to integrate...everything...into such a "small package"
...& then, trying to get everything to work together...IDK
&
Finding a 52V Lithium battery pack
...that can provide 80A
...isn't going to be cheap...either

As an 52V 80A BMS (Battery Management System)
...would probably cost more, than the batteries...themselves

For the BMS, I found a DALY 60a 14s BMS for 60 Canadian dollars....I could probably do 65a out of that which brings the max power to around 3.5kw, not bad. The engine comes with everything it needs to run, I would just have to hook up a servo to the throttle + choke and a MOSFET to control the starter relay. The engines should be relatively straight forward, and they each have their own sprocket and chain. For the size, the frame is custom made with no suspension , and I have about 14"x15" of space in the back for everything. the battery could be fitted under the kart, a 2p14s Molicel P42A with a cooling fan (battery cost ~ $390 Canadian dollars).

Does this sound more doable?

 

[TylersTrailRides]

Hello Everyone,

I have started to build a Hybrid Go-kart with a 2000w Vevor motor and a 212cc Pro Point + electric starter. The idea is to use an Arduino microcontroller to control the gas engine and electric motor. I was thinking of replacing the default controller with a ND72260 and running it off a 52v battery (3p14s BAK 45D). For the hybrid stuff, I will put a hall sensor on the flywheel, and another on the electric motor axle for rpm detection. Since the electric motor doesn't have a clutch and is directly connected to the rear axle, one hall is enough for both. When in the hybrid mode, the gas engine starts up at 25km/h and slowly throttle up until the rpm of the gas engine matches the rpm + 100 of the electric motor, so when the centrifugal clutch engages, there's a little bump handing the power from one power source to the other (or so I hope). Gas engine throttle is controlled by servo, so is choke. For the electric engine, throttle is controlled by a DAC from 0.8v - 4.2v

Gear ratio info:

212cc: 12t to 40t
2000w: 9t to 40t

Since the 2000w motor is only running a little bit at the beginning, I think it can take the 80a max of the controller, so a little above 4kw of power. The tires are 13" so a top speed of about 70km/h.

I have never done this before........any thoughts?

Do you have any updates? I just recently got one of those 125cc Mini Jeeps from Tractor Supply, and I was thinking about throwing a 72v KR5V motor on it as well. I'm kind of more worried about my electric motor blowing up the 125cc from over revving it. Was wondering if you have gotten the chance to solve that problem.

My other idea is to use QS205 Single Shaft Hub motors (the kinds that mount a 4x100 rim to them) and have them as the front two wheels for AWD but I cannot find anyone who stocks spindles that would be compatible with them.