Thursday 27 October 2011

The timing chain experience

Motorcycles use a small timing chain for ignition timing and who knew they would be ANSI-25... When we visited our local cycle wala, he was kind enough to shorten chains for us with a lot of questioning and unwanted advice

He couldnt just believe a vehicle could balance by itself
"بھائی بندہ منہ کے بل گر جائے گا ہاہاہا ! "

We got what we needed - this chain was available in the market and we had to shorten/extend it to get the desired length

How about opening a bicycle repair shop ? :D

Wednesday 12 October 2011

Shershah, Saddar, Lighthouse and PNEC Workshop

That reminds me, Karachi has become too polluted :(

One visit to Shershah kabari market was enough to stop hoping for two exactly same geared motors of our requirements although there were some pretty nice power gates, conveyer drive and german industry discarded motors(27Amperes, handling this current would be hell).
See how an expert does it ?

We purchased 250W,24V,14A electric scooter motors for PKR 1000 each. Says 2500 rpm on the plate but the tachometer measures 3000 rpm on 24v, unloaded speed maybe....It has an 11 tooth ANSI-25 sprocket. Meant to be coupled with electric scooter wheel.
This one turned out to be defective (tried placing the magnet back with epoxy but didnt work) and we had to make another covert strike on Shershah to get two more. It's always better to choose easily replaceable parts...

And here come the wheels from lighthouse... straight to the floor of EPE projects lab
The wheel had around 78 teeth. That gives almost a 7:1 gear ratio (78:11) but comes with a freehub (the ones that drive in one direction freewheel in the other). This was taken care of by expert advice from Majeed bhai :D
The freehub was disabled by welding around the bearing that allows unidirectional movement

Axle - the stick that does wonders....and of course the legendary phatta (plank)
Got the axle made to our designed dimensions from lathe machinist from Ranchor Lines (possible explanation Run=battlefield, Chor=Leave - maybe some general retreated to that place :P ) and the 10-layer ply from our very own pnec mechanical workshop.

The Operation Theater Table

Wheels and axle fitted, let's fix the motors


Assumption is the mother of screw up !!!





The roller chain looked so tiny, we completely overlooked the possibility it would be longer than needed :(