projects:hardware:jabel

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projects:hardware:jabel [2019/09/01 15:22] fantawamsprojects:hardware:jabel [2021/10/10 17:07] (current) metalgamer
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-<note important> Work in progress </note> 
- 
 ====== Jabel ====== ====== Jabel ======
  
 ^ Description | An electrical vehicle to transport heavy objects.... | ^ Description | An electrical vehicle to transport heavy objects.... |
-^ Status | Planning |+^ Status | Running |
 ^ Contact | [[user:fantawams|]],[[user:orimpe|orimpe]]| ^ Contact | [[user:fantawams|]],[[user:orimpe|orimpe]]|
 ^ Participants: | everybody | ^ Participants: | everybody |
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 As it is a pain in the ass to transport heavy stuff manually, it is a much smarter solution to transform a hoverboard into something, with which you can transport your stuff. Also you can recycle a hoverboard, as most of the time, the thing that is broker, is the gyro sensor or the battery. \\ As it is a pain in the ass to transport heavy stuff manually, it is a much smarter solution to transform a hoverboard into something, with which you can transport your stuff. Also you can recycle a hoverboard, as most of the time, the thing that is broker, is the gyro sensor or the battery. \\
  
-===== specs ===== +===== Specs ===== 
-=== basic construction ===+ 
 +=== Basic construction ===
  
   * steel: 2mm strength   * steel: 2mm strength
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   * total weight maximum of 5kg without motor or batteries   * total weight maximum of 5kg without motor or batteries
  
-=== motor ===+=== Motor ===
  
   * 4x4 hoverboard motors, each 250W sensored bruchless DC motors   * 4x4 hoverboard motors, each 250W sensored bruchless DC motors
  
-=== controller ===+=== Controller ===
  
   * RF controller   * RF controller
   * no power => stop (perhaps in version2)   * no power => stop (perhaps in version2)
      
-==== ideas for future versions ==== +==== Ideas for future versions ==== 
-=== realistic ideas ===+ 
 +=== Realistic ideas === 
   * led lights to see in the dark   * led lights to see in the dark
   * places to connect other Jabels or to fix stuff (perhaps in version 2), solution in the keep it stupid simple way   * places to connect other Jabels or to fix stuff (perhaps in version 2), solution in the keep it stupid simple way
 +  * suspension
 +  * auto drive button (aka press button and it drives with walking pace forward)
 +  * always on beeping
 +  * switch to disconnect battery
 +  * side pipes
 +  * Jabel convoy
 +
 +=== Crazy ideas ===
  
-=== crazy ideas === 
   * able to sit on it and drive it like a car   * able to sit on it and drive it like a car
   * 8x8 offroad jabel   * 8x8 offroad jabel
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 ==== Tips for future versions ==== ==== Tips for future versions ====
-Buy the steel at [[http://www.agrifer-acier.com/| Agrifer]], they will cut the pieces as needed for a cheap price. 
-Using not 2mm steel but 1 - 1.5 mm steel, to make it lighter. 
-Making the metal construction out of aluminium to make it lighter. Thickness should than be at least 2mm to maximum of 3mm. 
  
 +  * Buy the steel at [[http://www.agrifer-acier.com/| Agrifer]], they will cut the pieces as needed for a cheap price.
 +  * Using not 2mm steel but 1 - 1.5 mm steel, to make it lighter.
 +  * Making the metal construction out of aluminium to make it lighter. Thickness should than be at least 2mm to maximum of 3mm.
 +  * Start and stop button, better position.
 +  * Charge connector, better position.
 +
 +===== Software =====
 +
 +==== Building firmware ====
 +
 +<code>
 +make
 +</code>
  
-===== software ===== 
 The Jabel is another form of the [[https://github.com/NiklasFauth/hoverboard-firmware-hack/wiki/Build-Instruction:-TranspOtter#linux|TranspOtter]]. The main difference here, is that the Jabel is using an RF controller and the TranspOtter is using Gametrack to navigate. Find in the Link also other [[https://github.com/NiklasFauth/hoverboard-firmware-hack|Hoverboard hacks]]. The Jabel is another form of the [[https://github.com/NiklasFauth/hoverboard-firmware-hack/wiki/Build-Instruction:-TranspOtter#linux|TranspOtter]]. The main difference here, is that the Jabel is using an RF controller and the TranspOtter is using Gametrack to navigate. Find in the Link also other [[https://github.com/NiklasFauth/hoverboard-firmware-hack|Hoverboard hacks]].
  
-As we are using an RF controller, we need to slightly modify the firmware. So we open in the Inc folder the conf.h file and adjust the following. \\ +As we are using an RF controller, we need to slightly modify the firmware. So we open in the Inc folder the conf.h file and adjust the following. From
-From+
 <code> <code>
 // ############################### INPUT ############################### // ############################### INPUT ###############################
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 #define CONTROL_MOTOR_TEST_MAX_SPEED 300         // sweep slowly from -MAX_SPEED to MAX_SPEED (0 - 1000) #define CONTROL_MOTOR_TEST_MAX_SPEED 300         // sweep slowly from -MAX_SPEED to MAX_SPEED (0 - 1000)
 </code> </code>
-To+ 
 +To:
 <code> <code>
 // ############################### INPUT ############################### // ############################### INPUT ###############################
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 </code> </code>
 +
 +==== Flashing the mainboard ====
 +
 +It is possible on linux OS, we just could not get it working.
 +So we are sadly using the windows way with the official ST-Link software.
 +
 +
 ===== Version 1.0 ===== ===== Version 1.0 =====
-==== need to know ==== + 
-The firmware allows to use the hoverboard motors up to 40km/h. For the Jabel this is not what we want. The Power of an motor can be used, to get either a higher top speed, as for the bobbycar, or to get a higher torque. As a higher torque would allow us to transport a higher load or simply transport the load better, as we can get more strength out of the motor, we will try to slightly increase the software current limit in the firmware. Depending on how you adjust the firmware, you can increase the power output of a motor from 250W to 800W. This does not only sound nice, but also brings risk with it. So keep in mind: \\+==== Need to know ==== 
 + 
 +The firmware allows to use the hoverboard motors up to 40km/h. For the Jabel this is not what we want. The Power of an motor can be used, to get either a higher top speed, as for the bobbycar, or to get a higher torque. As a higher torque would allow us to transport a higher load or simply transport the load better, as we can get more strength out of the motor, we will try to slightly increase the software current limit in the firmware. Depending on how you adjust the firmware, you can increase the power output of a motor from 250W to 800W. This does not only sound nice, but also brings risk with it. So keep in mind: 
 add quote from spiderman add quote from spiderman
-\\ 
  
-The danger here is, that we are working with electrical motors. A higher torque means a higher current. The only thing, which is limiting the current in the motor is the internal resistance, which is very small, and   reverse voltage, when the motor is spinning. When the motor is not spinning or slowly spinning, we only have our small internal resistance, so a too high current will burn the motors. This is of course something we want to absolutely avoid. Another aspect of a high current, is that the battery, cables and mainboard need to be able to handle such an electrical load. \\+The danger here is, that we are working with electrical motors. A higher torque means a higher current. The only thing, which is limiting the current in the motor is the internal resistance, which is very small, and   reverse voltage, when the motor is spinning. When the motor is not spinning or slowly spinning, we only have our small internal resistance, so a too high current will burn the motors. This is of course something we want to absolutely avoid. Another aspect of a high current, is that the battery, cables and mainboard need to be able to handle such an electrical load. 
 + 
 +==== Basic construction ====
  
-==== basic construction ==== 
 {{ :projects:hardware:chassis.svg |technical draw of chassis}} {{ :projects:hardware:chassis.svg |technical draw of chassis}}
 The basic construction is made out of steel with 2mm strength. We cut the 30mm pipes to the right sizes. The basic construction is made out of steel with 2mm strength. We cut the 30mm pipes to the right sizes.
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 {{ :projects:hardware:side_pipes.jpg?200 |57cm pipes}} {{ :projects:hardware:side_pipes.jpg?200 |57cm pipes}}
  
-Than we welded 2x83cm pipes and 2x57cm pipes together, to have an chassis. The other 2 57cm pipes are used to have a sturdier chassis. It will be used to fix the batteries, mainboard and of course our bearing surface. \\ +Than we welded 2x83cm pipes and 2x57cm pipes together, to have an chassis. The other 2 57cm pipes are used to have a sturdier chassis. It will be used to fix the batteries, mainboard and of course our bearing surface. 
-{{:projects:hardware:welding2.jpg?200 |welding}}{{:projects:hardware:welding3.jpg?200 |welding}}{{:projects:hardware:welding.jpg?200 |welding}}{{:projects:hardware:basic_construction.jpg?200 |chassis}} \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\+ 
 +[{{:projects:hardware:welding2.jpg?200|welding}}
 +[{{:projects:hardware:welding3.jpg?200|welding}}
 +[{{:projects:hardware:welding.jpg?200|welding}}
 +[{{:projects:hardware:basic_construction.jpg?200|chassis}}
 As we decided to use only 2 motors for the first version, we had to improvise a fix for the hoverboard motors. There is a height difference of 9cm between the front wheels and the hoverboard wheels. To have an aligned surface later on, we welded 3 spare pieces together to fix the hoverboard motors onto the chassis. As we decided to use only 2 motors for the first version, we had to improvise a fix for the hoverboard motors. There is a height difference of 9cm between the front wheels and the hoverboard wheels. To have an aligned surface later on, we welded 3 spare pieces together to fix the hoverboard motors onto the chassis.
 {{ :projects:hardware:construction_with_mounts.jpg?200 |}} {{ :projects:hardware:construction_with_mounts.jpg?200 |}}
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 To be able to mount the front wheels and the hoverboard motors onto the chassis, we are using M8 screws. So we drill all the necessary holes into our chassis. \\ To be able to mount the front wheels and the hoverboard motors onto the chassis, we are using M8 screws. So we drill all the necessary holes into our chassis. \\
 {{:projects:hardware:drilling_holes.jpg?200|}}{{:projects:hardware:drilling_holes2.jpg?200|}}{{:projects:hardware:drilling_holes_3.jpg?200|}} \\ {{:projects:hardware:drilling_holes.jpg?200|}}{{:projects:hardware:drilling_holes2.jpg?200|}}{{:projects:hardware:drilling_holes_3.jpg?200|}} \\
-After this we simply mount all the wheels on it. \\+After this we simply mount all the wheels on it. 
 {{ :projects:hardware:basic_construction2.jpg?400 |}} {{ :projects:hardware:basic_construction2.jpg?400 |}}
 +
 +==== Wooden surface ====
 +
 +The wooden surface is used to hold all the heavy stuff while transportation. 64,5cm x 84,5cm.
  
 ==== Battery ==== ==== Battery ====
-As we want to have enough energy to transport all the stuff with the Jabel, we need an strong enough power source power source. Fro this purpose we are going to build a battery out of old lion cells. 
  
-An original hoverboard battery, is a 10s2p battery with 18650 type lion cells. This means 10 cells in serial with 2 in parallel. They have around 42V and around 4400mAh. This is enough for around 30 minutes driving.As we want to increase this time, we simply need more energy stored in our battery. The limits what a hoverboard mainboard can handle is around 55V.+As we want to have enough energy to transport all the stuff with the Jabel, we need a power source that is strong enough. For this purpose we are going to build a battery out of old lithium-ion cells. 
 + 
 +The original hoverboard battery, is a 10s2p battery with 18650 type lion cells. This means 10 cells in series with 2 in parallel. They have around 42V and offer around 4400mAh. This is enough for about 30 minutes of driving. As we want to increase this time, we simply need more energy stored in our battery. The maximum voltage a hoverboard mainboard can handle is around 55V.
  
 Every battery should have an internal balancer to protect against: Every battery should have an internal balancer to protect against:
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   * 12s4p   * 12s4p
   * 10s6p   * 10s6p
 +  * 11s5p <-
   * 11s6p   * 11s6p
   * 12s6p   * 12s6p
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   * 11s8p   * 11s8p
   * 12s8p   * 12s8p
 +
 +{{:projects:hardware:jabel:bat0.jpg?direct&400|Aubbau inklu des Punktschweissgerätes}}
 +Hier der Aufbau während des zusammenbaus.
 +
 +{{:projects:hardware:jabel:bat1.jpg?direct&400|Nahaufnahme der Brücken}}
 +Nahaufnahme der Brücken
 +
 +{{:projects:hardware:jabel:bat2.jpg?direct&400|Fertiger Akku}}
 +Fertiger Akku, jetzt fehlt nur noch das Batterie Management System (BMS)
 +
 +=== Arbeitsmaterial ===
 +
 +  * [[https://www.keenlab.de/index.php/product/kweld-complete-kit/|kWled]]
 +  * Autosbatterie als Stromquelle
 +  * Schere
 +  * Nickelband
 +  * [[https://www.ebay.de/itm/4x5-Cell-18650-Batteries-Spacer-Radiating-Shell-Plastic-Heat-Holder-Bracket/232495802404?hash=item3621d46824:g:oOgAAOSwScdZwzFS|4x5 Cell 18650 Batteries Spacer]]
 +  * alte Li Ion 18650 Zellen (in diesem Fall 55 Stück)
  
 ==== Battery case ==== ==== Battery case ====
 +
 Having a powerful battery is nice and fine, but without a case it will be difficult to mount it on the Jabel. It also serves a protection against stones, water and dirt. Having a powerful battery is nice and fine, but without a case it will be difficult to mount it on the Jabel. It also serves a protection against stones, water and dirt.
  
 ==== PCB protection ==== ==== PCB protection ====
-The PCB mainboard needs a mechanical protection against water and dirt. 
  
 +The PCB mainboard needs a mechanical protection against water and dirt. For this purpose, we are using a medium junction box. It has enough space for the mainboard and reserve for other PCBs if needed.
 +
 +==== Fancy stuff ====
  
-==== fancy stuff ==== 
 As the Jabel is build by hackers and as hacker simply love LEDs, we are equipping it with LEDs and LED strips. These have not only the effect to make the whole thing look nice and fancy, but also have an useful purpose.Atnight you can still see where you are driving or simply see where the Jabel is. As the Jabel is build by hackers and as hacker simply love LEDs, we are equipping it with LEDs and LED strips. These have not only the effect to make the whole thing look nice and fancy, but also have an useful purpose.Atnight you can still see where you are driving or simply see where the Jabel is.
  
-===== sources =====+===== Sources ===== 
   * [[https://www.google.com/imgres?imgurl=https%3A%2F%2Fimages-na.ssl-images-amazon.com%2Fimages%2FI%2F41JOAcnH0BL._SX331_BO1%2C204%2C203%2C200_.jpg&imgrefurl=https%3A%2F%2Fwww.amazon.com%2FGreat-Power-Comes-Responsibility-Superhero%2Fdp%2F1097590836&docid=ub0wFEkMLDrtnM&tbnid=odSFSVkfASV9pM%3A&vet=10ahUKEwi76a3exKrkAhViSxUIHTRuBCUQMwh_KCwwLA..i&w=333&h=499&bih=581&biw=1227&q=with%20great%20power&ved=0ahUKEwi76a3exKrkAhViSxUIHTRuBCUQMwh_KCwwLA&iact=mrc&uact=8|spiderman quote]] or [[https://www.google.com/search?tbm=isch&q=with+great+power&chips=q:with+great+power,online_chips:quote,online_chips:spider+man,online_chips:responsibility&sa=X&ved=0ahUKEwixtIGJg6vkAhU0RhUIHSh9CvYQ4lYIKygA&biw=1227&bih=581&dpr=2.61#imgrc=fBBzFYyuyXNL2M:| spiderman quote]]   * [[https://www.google.com/imgres?imgurl=https%3A%2F%2Fimages-na.ssl-images-amazon.com%2Fimages%2FI%2F41JOAcnH0BL._SX331_BO1%2C204%2C203%2C200_.jpg&imgrefurl=https%3A%2F%2Fwww.amazon.com%2FGreat-Power-Comes-Responsibility-Superhero%2Fdp%2F1097590836&docid=ub0wFEkMLDrtnM&tbnid=odSFSVkfASV9pM%3A&vet=10ahUKEwi76a3exKrkAhViSxUIHTRuBCUQMwh_KCwwLA..i&w=333&h=499&bih=581&biw=1227&q=with%20great%20power&ved=0ahUKEwi76a3exKrkAhViSxUIHTRuBCUQMwh_KCwwLA&iact=mrc&uact=8|spiderman quote]] or [[https://www.google.com/search?tbm=isch&q=with+great+power&chips=q:with+great+power,online_chips:quote,online_chips:spider+man,online_chips:responsibility&sa=X&ved=0ahUKEwixtIGJg6vkAhU0RhUIHSh9CvYQ4lYIKygA&biw=1227&bih=581&dpr=2.61#imgrc=fBBzFYyuyXNL2M:| spiderman quote]]
   * [[https://github.com/NiklasFauth/hoverboard-firmware-hack|original firmware ]]   * [[https://github.com/NiklasFauth/hoverboard-firmware-hack|original firmware ]]
  • projects/hardware/jabel.1567344165.txt.gz
  • Last modified: 2019/09/01 15:22
  • by fantawams