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The delta T isn't much, particularly on a hot day, but you have the same situation with the passive (stock) thermal mgmt system but without the torturous and limited thermal path. However, I'm incorporating a thermostat which senses the cold plate temperature and won't turn on the pump until it...

Bike is ready for initial testing

Temporary installation of water pump, good enough for testing. Fan pulls air through the radiator. Thanks for the kind words BH. Back at you for sure.

Here's some simulation I did using ANSYS. The first is pack temperature during heavy discharge and subsequent charging. Essentially, it shows that after about 1.5 hrs of charging the pack would be around 53 C (without any mist cooling) assuming standard ambient conditions. Thermal limiting...

MSC Engineering is almost ready to test my water cooled Alta battery pack. Pack is ready to be swapped into my bike but need to finish all the plumbing first. System uses a small electric pump, remote radiator and a modified Alta pack. Currently, the pack has only two of the four modules...

Oh yes, I didn't even notice the fault occurred during charging, thanks Raakesh for helping "isolate" haha, the problem. The DCCP has two wires that carry the hi voltage (+/-) from the charge port (charger connected) down to the inverter where they're ultimately connected to Bus +/- at the...

Be very careful with that one. Isolation refers to the physical separation (in terms of resistance/ohms) between the high voltage electronics/electrical system and the low voltage system. Ideally, you want the two to be completely isolated from each other. In practice the Alta typically...

Typically about 15-20% difference.

SRod's Cat, that's deep stuff. lol.

Right now I'd say it's 75% physical mod and the rest programming. I say "right now" because the problem is still present under the right (wrong) conditions. The Sevcon is a tougher nut to crack compared to the ASI that's for sure. However, as you mentioned, the higher voltage capability of...

I think I have it 90% solved. It all depends on the rider and the situation. If you're not personally getting the fault I wouldn't worry about it.

And I remember a time when us early Alta owners were begging the factory to provide this tool! They never did . . . . . . .

Embarrassing!

The one P group has at least one wire bond failure. The lower capacity of that P group results in voltage differences shown (faster discharge/lower voltage during use and faster charge/higher voltage during charging). It'll cause the system to hit the low voltage cutoff before the other 83 P...

Thanks for the kind comments, both you guys (Bob and Don). The ASI controller's current control algorithms are pretty darn good, so once you get the motor characterized properly it's typically all just fine tuning. This makes the whole process pretty easy and the results are typically quite...

I’ll showcase a few of my converted bikes if they’ll pay for shipment and travel, lol.

In my opinion, regardless of whether they changed the process or not, wire bonds to a cells shoulder are inherently more susceptible to breaking under stress than otherwise. Therefore, although reliability may be improved it’s still going to be prone to failure over time. My opinion.

Nope, just normal outdoor MX (LACR for those SoCal followers). Of course, "normal" today means clearing some horrendously long gaps and coming up short or going long isn't always the most enjoyable experience for bike or rider, lol.

Some of our Alta owners jump long and land hard!

Here's my latest design layout . . . . . the linkage rate is much less progressive and almost identical to a modern linked rear suspension. The addition of a second link was the key. The relocation of the rear suspension opens up so many opportunities in terms of component layout and allows...