This dual- motor electric bike is a well- engineered example. This is an awesome All- Wheel- Drive E- bike, and it is also a folder so that it can be carried onto a train for day- trips to the mountains. It has been designed and built by a brilliant guy named Ben, and we are already quite familiar with him, because. In fact, the inspiration for this bike came from an incident when Ben was riding Dogati up that very hill when returning to his home, and in a brief moment of using too much power!
While resting from an injury that happened during that fall? He enjoys taking day trips to the nearby mountains on the train, and bringing a full- sized E- bike had proven to be problematic in the past, but. Most folding frames are not as strong as their one- piece version, but the Paratrooper is the strongest folding frame available anywhere. The strength of this frame was a deciding factor, but it’s also nice that the well- designed folding mechanism allows it to be deployed or stowed in less than 2. Be aware that there are many cheap clones of the Paratrooper frame that are easy to find on the web for purchase. Although they look similar, they will not be as strong as an authentic Montague Paratrooper. The Montague Paratrooper bicycle in the folded position, with it’s travel bag.
Ben wanted to design and document his take on a DIY pack made from the increasingly popular 1. These cylindrical cells (found inside cordless tool batteries), are now available in high current models that are not made from the risky Li.
Po (which has previously been the popular battery chemistry for high performance). He chose the excellent NCR1. PD cell from Panasonic, and then settled on a 1. S / 7. P configuration. If charged to 4. 1. V per cell, a pack configured of sub- packs (with 1. Series (1. 4S) would be 5.
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V when fully charged. Part of this decision was because Paul at em. So, 5. 7V X 2. 0- Ah = an awesome 1. Watt Hours (WH) of capacity. Our experience has shown us that if a rider adds mild pedaling half the time (which is normal), a geared hub E- bike uses about 2. WH per mile. Using that as a measuring stick, this 1. WH pack should average 5.
H). That sounds like a pretty outrageous claim for such a small pack, but. The thin wires are for balance- charging each 7- cell paralleled sub- pack. The amber colored film is Kapton tape, which is a final layer of non- conductive protection against shorts.
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The final touch was adding a hard plastic shell to protect the pack from the minor bumps that are a normal part of life. Ben knew he wanted a triangle shape for his battery pack, but the dimensions of a triangle can vary widely. The pack size and specific layout of his cells match a specific heavy- duty bag made by Revelate, and it was designed to match frames from Salsa Cycles. This particular bag is the “El Mariachi“. A triangle frame bag from Revelate, designed for Salsa bicycles. High- end battery packs can cost as much as $1,0.
He recently stumbled across a key- locking seat- post clamp during his searches, which was designed to protect bicyclists from having their expensive saddles stolen. Ben realized that if a cylindrical post- stub (the same diameter as a seat- tube) was bolted under his top- tube, this clamp could be re- purposed to act as a pack lock. He ordered two large 3. Here’s a close- up of the key- lock seat- tube clamps which have been re- purposed as battery pack locks. In the pic on the left, Ben inserted an 8mm Rivnut into the bottom of the top- tube, and he then bolted a 2. Rivnut. In the right pic, Ben made a 2. Two sets of these clamps completes a solid battery attachment and anti- theft system.
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The fork’s axle- clamping bolt is not strong enough to resist the motors’ torque so he added a set- screw through the top. The wheel is still easy to remove for fixing flats and replacing tires, wires and all.
Here’s a close- up of the custom axle- sleeve that allows a stock MAC axle to fit into an upgraded suspension fork that normally takes a heavy- duty “pass- through” axle. If the name em. 3ev. He is now our number- one suggestion for high current batteries that are NOT Li.
Po. The MAC geared hub is well- known around ES, and its performance has earned it the right to be the most- often suggested kit for the majority of new E- bike enthusiasts. Geared hubs are smaller and lighter for a given torque, compared to the slightly less expensive direct- drive (DD) hubs. For a dual- motor set- up, geared hubs have the feature of a built- in freewheel, and this alleviates several issues that would affect the bike if you used two DD hubs. The fact that these motors are light and they freewheel? The less- expensive Bafang- BPM is one of the most commonly sold geared hubs on the planet, and it is roughly the same diameter as the MAC.
However, the BPM’s stator is 1. MAC’s is 2. 2mm wide. This means the MAC is capable of roughly 2. Both of those motors are also excellent choices. One of the benefits of buying a MAC from Paul at em. Once he had two of these motors, they didn’t seem to struggle at all with the loads he was putting on them, so he swapped- in two 6.
T MACs which provide a faster 7. MPH). Once you add a second motor to the calculation, your E- bike has the copper mass to be able to use 3,0. W of peak power. And.
This is an important calculation, because by designing the system to work well at only 5. A from each paralleled sub- pack of seven cells (7. P), each individual cell only has to provide a temporary peak of 8 amps (these cells are rated for 1. A peak). All three use two identical geared hubs. They use a single throttle, a single battery. Under the loads Ben is using, they both stay cool (3.
A peak each for a total of 6. A, and perhaps 1. A continuous). This allowed Ben to mount both controllers in a bag behind the seat without any danger of overheating. This set- up can use a temporary peak of 3,0. W, and to equal that performance with a single motor, Nicobie’s e.
Townie and also. Both approaches to achieving a reliable 3,0. W of performance have been proven to work, but splitting that amount of power between two motors and two controllers. Also, by mounting the batteries weight in the center and putting the motor weight split between two of them at each end, this E- bike has a very balanced feel when riding. When only pedaling (as rare as that may be with a high- powered E- bike) the geared hubs will. Also, with the dual motors, you have the option of using a single smaller motor, which can help your range on flat land. One of the biggest benefits is the system redundancy. This may be a vital characteristic in a very hilly community.
And of course, in wet weather or snow & sand, the added traction of AWD cannot be equaled by a single motor E- bike, no matter how much power it may have. Ben wrote to me that he recently swapped- in fatter tires: “One day my buddy (ES member: ghettoracer) and I were ripping down a fairly steep mountain when we encountered some slower scooter/car traffic on a narrow road. After miles of slow drafting we saw an opportunity to pass so we gunned it. After the pass, my friend hit the front brakes a little too hard as we were passing over some gravel and his front end slid out. He was riding the black Duty Cycle AWD with narrower 1. I saw him go down in a split- second and immediately stopped and went back to block any oncoming traffic.
Luckily he suffered only a few minor scrapes and bruises. After that incident I went out and bought Schwalbe Big Ben 2. X 2. 3. 5. I learned that a good set of “substantial” tyres is a mandatory requirement when you are running this type of high- power AWD setup. Using 5. 0/5. 0% power distribution, the front wheel has a tendency to spin- out.
Next on the to- do list for Duty Cycle will be a variable control for altering the front/rear power distribution.