Trystan Casey
Building a mini electric skateboard is a complex process that requires knowledge of mechanics, electronics, and design. It involves significant engineering and can be a challenging yet rewarding endeavour. The process begins with selecting the right parts, such as motors, speed controllers, and batteries, and progresses to assembling the components and ensuring proper wiring and optimisation. Safety is a critical consideration, and wearing a helmet is essential when riding electric skateboards. With careful planning, it is possible to build a high-performance electric skateboard on a budget that rivals consumer brands in terms of speed and range.
| Characteristics | Values |
|---|---|
| Motor | Brushless out-runners for rc planes are commonly used. A brushless dc motor is recommended for its power. |
| KV-ratio | The higher the KV, the lower the torque (force) the motor can output. The usable KV-ratio for electric skateboards is between 100 and 300 KV. |
| Speed Controller | A speed controller that can support very high amps. |
| Battery | Lithium Polymer (LiPo) is commonly used. |
| Deck | A longboard deck is recommended for more stability and a smoother ride. |
| Design | Drawing a rough sketch of the components and their layout is helpful. |
| Materials | Brushed aluminium, carbon fibre, and vinyl are some materials used. |
| Kits | Electric skateboard kits are available to simplify the building process. |
| Performance | Electric skateboards can reach speeds of 20-40 mph, with a range of 6-20+ miles per charge and the ability to climb hills. |
| Braking | Regenerative braking can increase the range of the skateboard. |
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What You'll Learn
Choosing the right motor
Motor Type:
The type of motor you choose will significantly impact your skateboard's performance and ease of use. The three common types of motors used in electric skateboards are outrunner motors, hub motors, and direct drives. Outrunner motors tend to have higher power outputs, making them a popular choice for those seeking speed and performance. Hub motors, such as the Enertion Raptor 2, are known for their high torque and are a good option if you want to maintain torque while keeping the KV lower. Direct drives are another option, but they require a more complex setup and are less commonly used in electric skateboards.
Motor Size:
Motor size plays a crucial role in both the power output and the physical dimensions of your skateboard. Motors are typically denoted by a four-digit number, with the first two digits representing the diameter and the last two digits indicating the length. For example, a 6380 motor has a diameter of 63mm and a length of 80mm. A larger motor diameter generally equates to more power, but it also adds weight to your setup. If you're looking for a lightweight skateboard, consider a smaller motor like a 5055 or 6355, keeping in mind that smaller motors may overheat under aggressive riding conditions.
Power and Torque:
The power of electric skateboard motors can vary significantly, ranging from 250W to 350W for simple hub motors, while more powerful options like the Enertion R-Spec Ghost hub motor can reach 1680W. Outrunner motors typically have higher power outputs, with DIY options ranging from 1000W to 4000W. When selecting a motor, ensure that the maximum current it can pull is compatible with your Electronic Speed Controller (ESC). Additionally, consider the KV rating, which represents the number of revolutions per minute (RPM) the motor makes when 1 volt is applied. A higher KV means a faster motor but lower torque output. For electric skateboards, the usable KV-ratio typically falls between 100 and 300 KV.
Single vs. Dual Motor:
Finally, decide whether you want a single or dual motor setup. A single motor electric skateboard will be lighter and easier to carry, but it may struggle on steep hills. On the other hand, a dual motor setup provides more power and better braking capabilities, making it ideal for navigating inclines.
In summary, choosing the right motor for your mini electric skateboard involves considering motor type, size, power, and torque, as well as deciding between a single or dual motor setup. Remember to refer to online forums and manufacturer specifications to make an informed decision based on your specific requirements and riding style.
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Selecting a speed controller
When selecting a speed controller for your mini electric skateboard, there are several factors to consider. Firstly, it is important to understand the role of a speed controller in an electric skateboard. A speed controller, also known as an Electronic Speed Controller (ESC), is responsible for regulating the speed and direction of the skateboard. VESC (Vedder Electronic Speed Controller) is an advanced version of ESC, offering enhanced features and performance.
To choose the appropriate speed controller, consider the following key factors:
- Motor compatibility: Ensure that the speed controller is compatible with the motor of your mini electric skateboard. Different motors have varying power requirements, so selecting a speed controller that matches your motor's specifications is crucial.
- Power requirements: Evaluate the power needs of your electric skateboard setup. Consider the voltage and current requirements, as well as the KV-ratio (rpm/Volt applied to the motor). Selecting a speed controller with adequate power handling capabilities is essential for optimal performance.
- Customization and features: Determine the level of customization and features you desire. Some speed controllers offer advanced options and settings, allowing you to fine-tune your riding experience. Consider your specific needs and preferences to choose a speed controller that provides the desired level of customization.
- Performance and compatibility: Opt for a speed controller that ensures optimal performance and compatibility with your electric skateboard setup. The right speed controller will enhance your riding experience by providing smooth and responsive speed control.
- Safety features: Prioritize speed controllers that incorporate safety features. Look for options that include regenerative braking, speed limiters, or other safety mechanisms to ensure a secure riding experience.
- Reviews and recommendations: Conduct thorough research and read user reviews to gain insights into the performance, reliability, and durability of different speed controllers. Consult with experts or experienced riders to gather their recommendations and advice on selecting the most suitable speed controller for your needs.
It is important to note that the speed controller is a critical component of your mini electric skateboard, impacting its performance, control, and overall riding experience. Therefore, taking the time to research and select the right speed controller, such as a high-performance VESC, is essential to ensure compatibility, safety, and enhanced functionality.
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Designing the layout
Firstly, gather all the components and lay them out on a flat surface. This includes the electric motor, speed controller (ESC), receiver, receiver pack, batteries, and any other parts you plan to use. Sketch a rough outline of each component on a piece of paper to visualize their placement. The goal is to organize the components in the most compact and efficient way, ensuring they fit within the dimensions of the skateboard deck.
Consider the airflow and cooling of the electronic components. Mesh at either end of the layout can enhance airflow, helping to keep the electronics cool during operation. Secure the batteries in place with tapered ends, allowing adequate space for cable routing.
Secure the ESC, receiver, and receiver pack using double-sided foam or other suitable adhesive materials. Plan the wiring path between the battery and ESC to ensure the wiring is protected and doesn't interfere with other components. If needed, drill holes or channels in the deck to accommodate the wiring.
When positioning the motor, consider its proximity to the wheels and the pulleys that will transfer power to them. Ensure the pulleys are the correct size and align properly with the motor shaft and wheels. You may need to adjust or drill the pulleys for a perfect fit, as mentioned in the Instructables guide.
Finally, think about the aesthetics and materials used for the bottom plate and deck. Brushed aluminium or carbon fibre vinyl can provide a sleek and durable finish. Keep in mind that you can always simplify the design or use a project enclosure to save time and effort.
Remember, safety should be a priority when designing and building your mini electric skateboard. Always wear protective gear when testing and riding your skateboard.
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Attaching the pulleys
Firstly, ensure you have the correct pulleys for your setup. The drive train kit mentioned in the source includes two pulleys, which is standard for electric skateboards. However, it's important to verify that the pulleys are compatible with your specific components.
Now, let's address the issue of the pulley's bore diameter. The smaller pulley, which attaches to the motor shaft, typically has an inside bore diameter of 8mm, while most electric skateboard motor shafts measure 8mm in diameter. However, in this case, the motor shaft is 10mm in diameter, requiring a larger hole in the pulley. To resolve this, carefully drill a larger hole using a 10mm drill bit and a drill press. Ensure the hole is straight and free of burrs or debris.
Next, you'll want to secure the pulleys firmly in place. The source indicates that screws and bolts were provided with the drive train kit, which can be used for this purpose. Ensure that the screws and bolts are of the appropriate size and thread type for your components. It's important to follow any manufacturer instructions or torque specifications provided with your hardware.
Finally, inspect your work and ensure that the pulleys are securely attached and aligned correctly. Verify that any belts (if applicable) are properly seated in the pulley grooves and that there is no binding or interference with other components. A proper installation will ensure smooth power transmission and help prevent premature wear or failure.
By following these steps and paying close attention to compatibility and secure attachment, you can effectively attach the pulleys to your electric skateboard, bringing you one step closer to enjoying your custom ride.
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Wiring the battery
When wiring the battery, it is important to follow a wiring plan or diagram to ensure the correct placement and connection of components. The battery cells' configuration, whether in series or parallel, will impact the voltage and Ampere Hours. Li-ion batteries are the most common type used in commercial boards, while LiPo batteries are popular among hobbyists due to their lower cost and reduced voltage sag. However, LiPo batteries require careful handling to prevent safety hazards and specific storage procedures.
To begin the wiring process, lay out the components and sketch their placement to ensure a compact and organized design. Secure the battery cells with tapered ends or holders to prevent movement and allow for adequate cable routing. Follow the wiring diagram to extend the wires as needed, using soldering and covering the joints with heat shrink tubing or electrical tape for insulation and protection. Ensure the battery connections are secure and soldered correctly, following the series or parallel configuration required for your battery type.
Additionally, consider the ESC (speed controller) connection. Solder the ESC's female bullet connectors to the 3-phase wires to allow for motor swapping if needed. Place the electronics in the enclosure, using velcro tape to secure them and prevent damage from bouncing. Organize the wires according to the wiring diagram, ensuring a neat and tidy setup. Finally, test the connections and ensure the wiring is secure and insulated to prevent electrical shorts.
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Frequently asked questions
A brushless DC motor is recommended for electric skateboards because of the power it can deliver in a small motor. The KV-ratio is very important for these motors. KV stands for rpm/Volt applied to the motor. The higher the KV, the lower the torque (force) the motor can output. The usable KV-ratio for electric skateboards is between 100 and 300 KV.
An ESC is a speed controller. You will need one that can support very high amps. The easiest way to choose is to get one that your chosen motor and batteries can plug straight into.
Most people use Lithium Polymer (LiPo) batteries. You will need at least a 10s battery.
A longboard deck is recommended as it gives you more stability, a smoother ride and more space for your components.
There are many online guides and videos that can help you build your electric skateboard. You can also find electric skateboard kits that include all the parts you will need.
