Electric Scooter Upgrade

Electric Scooter Upgrade

Project Brief
This small electric scooter is great fun to ride, but it only does 20kph. It needs to be given the Virtual treatment. More range. More speed. More power!
Requirements
The original drive system used a brushed DC motor and lead-acid batteries. Modern DC brushless motors and lithium batteries have a much higher power density in similar package sizes. So we need to rip out the old drive system and start over. We also needs to fit lights and indicators to use it on the road.
Outcome
A new brushless DC motor was fitted in place of the old brushed one. Six lithium battery packs rest where the old lead-acids used to be. A custom-developed analog throtellizer converts the hall-effect throttle signal into a servo pulse for the RC brushless motor controller. Headlights, brake lights, and indicators are wired to handlebar-mounted controls.
With a new high-power drive system in place, this little scooter hits 50kph real fast. The controller supports regenerative braking, which is just as well because the tiny original drum brakes are not adequate at this speed!
Original Specs
• Vego SX-600 electric scooter
• 600W brushed DC motor
• Lead-acid battery pack 24V, 22Ah
• Top speed: approx 20kph
• Range: approx 15km
Upgraded Specs, Virtual style!
• Turnigy TR80-100-A brushless outrunner motor, 7kW rated power
• Castle Creations Mamba Monster controller
• 6x Turnigy 6S 5Ah LiPo battery packs, total capacity 22V 30Ah, 600A peak discharge current
• Custom analog throtellizer supporting regenerative braking input
• Top speed: 55kph
• Range: approx 30km

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