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BuildinginstructionsCarlaCargoCrowdpostfossilmobile

BuildinginstructionsCarlaCargoCrowd
Frompostfossilmobile

TableofContents
1Foreword
2License
3Disclaimer
4Safety
5resources
6SocialMedia
7Sgetabelle
8Tools
9sideframewithoutriggersLINKS
10sideframewithoutriggersRIGHT
11connectingthesideframes
12impellerintakewithbrakesaddle
pickup
13stemandsteerer
14bossaccommodatingtofork
15pullline
16coupling
17andthereyougo...
18engine
19Thanksgiving

Foreword
Thebicycleisstilloneofthemostefficient,safestandmostspacesavingmeansoftransportintheworld.Theincreasinglypowerful
electromotorsforthebicyclemakecompletelynewbikeconceptspossible.Itisourchancetoreplaceobsolete,dirtyenginesbasedoncombustion
engines.Wewantcitiesinwhichpeoplearethefocus.Wewantmorespacetolive.Thismotivatesusandisourgreatestdrive.That'swhywe
[CarlaCargo(http://www.carlacargo.de)developed].
Wemakebikenotcar!

license
CarlaCargocrowdofCarlaCargo(http://www.carlacargo.de)islicensedunderaCreativeCommonsAttributionShareAlike4.0International
license(http://creativecommons.org/licenses/bysa/4.0/).ItthusmeetsthecriteriaoftheOpenSourceHardwareAssociation
(http://www.oshwa.org/definition/german/)andisopensourcehardware.

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IfyoumakeaCarlaCargoclone,thenpleaseletusknowandwriteusanemail.Wewilltrytosupportyouasmuchaspossible.
PleasebringaCarlaCargostickerontheframeandcontinuetheCarlaCargoStory(stickersareavailablewithus).
Ifyouwanttosupportourworkfinancially,youwillfindthenecessaryinformationonourhomepage.
SinceitispossiblewithCarlaCargotoreachaverywidepossibleuserfield,thepromotionchancesareveryhigh.Wecanonlyexpressit,
donotpointtostopattheconductionofbuyingaCarlaCargoortheconstructionofaCargoCarlaCrowdclone(http://www.bollebonn.de
).
WewouldlovetoshareyourexperienceswithyourclonewiththeothershereintheWiki.CarlaCargoCrowdclones

Disclaimerofliability
CarlaCargoacceptsnoliabilityforthisselfconstructionprojectdescribedhere!>youbuildweshare
CarlaCargocannotguaranteethecorrectnessofthismanual!>firstthinkthancut
Ifyouhaveneverwelded,youshouldfirstgainexperiencebeforeventuringonsuchareplica!
ThefulfillmentoftheStVOisyourresponsibility!

safetyinstructions
Warningofeyeinjuries,sparksandburns
Weldingalsoinvolvesseveraldangerouspossibilitiesofinjurywhichmustbestrictlyexcludedthrough
preventivemeasures.Therightprotectiveclothingisthebasisforsuccessfulandsafewelding.
Useofleatherglovestoprotectagainstsparks.
Useofaprotectivegogglesuitableforwelding.
Wearofclosedstablefootwear.
Wearingmaterialheavyworkclothesandpossiblyeventheuseofleatheraprons.

Dangerhighvoltage
CarlaCargocanbeusedwithhighvoltage,especiallywhenusingandbuildingCarlaCargowithengine
technologyandaccumulators.

Warningofcuts
Cuttinginjuriesmayoccur,particularlywhenusingflexandmitersaw.
Ensureadequateprotectionby,forexample,wearinggloves.
Ensurecorrectoperationofthemachines.Letmotorsrunout,forexample.

Warningofeyeinjuries
Theremaybeeyeinjuriescausedbysparks,especiallywhenusingflexandweldingequipment.
Ensureadequateprotectionby,forexample,wearingallencompassinggoggles(Flex).

resources

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CarlaCargoCrowdonGrabCad
(https://grabcad.com/library/carlacargo
crowd1)
2Ddrawings
STEPfile
DXFFiles
Constructiondata

2Ddrawings
frame
Kickwheelhubfrontwheel

SocialMedia
IfyouliketheCarlaCargoidea,letothersknow.
[www.carlacargo.de(http://www.carlacargo.de)]
[Entryinthenewsletter(http://newsletter.carlacargo.de/)]
[Blog(http://newsletter.carlacargo.de/blogde/)]
[Facebook(https://www.facebook.com/CarlaCargoTrailer)]
[Twitter(https://twitter.com/carlacargo)]
[Youtube(https://youtu.be/o1x9q2gixeA?list=PLiWbSGo_ymwVM4dwZeRwCrxSZ0dGhKfb)]
[Flickr(https://flic.kr/s/aHsjT2a4cH)]

Sawingtable
Stainlesssteel
3x20x20x1.5x6000mm
1x20x10x1,5x6000mm
1x20x50x1.5x6000mm
1x15x15x1,5x6000mm(onlyforpullrods)
1x20x20x2x6000mm(actuallyonlyverylittleofthis)
1x40x3x6000mmFlatironforpossibleimpellermountandtriangle
Note:Thisisonlyaroughoverview.Dependingonhowyoucanimplementthewholethingcanvarygreatly.That'swhybeforeyoumadeprecise
thoughtslikeyouwanttodothewholething.
frame
position

crosssection

Angleleft

Angleright

length

number

20x20x1.5mm

90

90

1625mm

20x20x1.5mm

90

90

150mm

20x20x1.5mm

90

90

110mm

20x20x1.5mm

60

60

152.5mm

20x20x1.5mm

60

72.5

1400mm

20x20x1.5mm

55

72.5

230.1mm

20x20x1.5mm

90

90

112mm

8th

20x20x1.5mm

60

90

53.8mm

20x20x1.5mm

60

90

53.8mm

10

20x20x1.5mm

90

90

610mm

11

20x10x1.5mm

90

90

610mm

10

20x50x1.5mm

90

90

110mm

11

20x50x1.5mm

90

90

400mm

12

20x50x1.5mm

90

90

200mm

13

20x50x1.5mm

90

90

200mm

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Commonlyusedsteelcrosssections.

Crankshaftlinkage
position

crosssection

Angleleft

Angleright

length

number

20x20x1.5mm

30

30

150mm

20x20x1.5mm

15

45

150mm

20x20x2mm

90

90

100mm

20x20x2mm

90

90

150mm

15x15x1.5mm

90

90

850mm

15x15x1.5mm

90

90

30mm

tools
Weldingmachine(TIGwelding)withaccessories
2xanglegrinder(1xcuttingdisc,1xfangrinder)
Feilassortment
drillingmachine
Machinevise,screwclamp
Waterweighingandtarpaulin
Weldingmagnets
Relevantprotectiveequipmentforrelevantwork
Assortmentoftines
pipecutters
StandDrillingMachineandCanDrill(33and40mm)
Metalmitersaw(manuallyoperatedoptional)
Anglelock

SideframeswithoutriggersLEFT

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001
Weldingsteelframeswiththeaidofweldingmagnets
Repeatdiagonalswithmeasuringtapeagain
Firstpoint,thenweldfromoutsidetoinsidetoavoidwarping
Grindweldseams

002
Twist20x10innerstruts

003
BoomLEFT
Boomwiththehelpofweldingmagnets.
Payattentiontotheorientationofthepage.20x10mmprofilesare
outside.

004
Supportprofilesanpoints.
Forweldingitcanbesensibletofixitwithscrewclamps.

SideframeswithoutriggersRIGHT

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005
Weldingsteelframeswiththeaidofweldingmagnets
Repeatdiagonalswithmeasuringtapeagain
Firstpoint,thenweldfromoutsidetoinsidetoavoidwarping
Grindweldseams

006
Twist20x10innerstruts

007
OutriggerRight
Boomwiththehelpofweldingmagnets.
Payattentiontotheorientationofthepage.20x10mmprofilesare
outside.

008
Supportprofilesanpoints.
Forweldingitcanbesensibletofixitwithscrewclamps.

sideframes
009
Alignthesideframesbymeansofweldingmagnetson20x20mm
profilesatrightangles
Startbelow,justscorepoints
Correctanywarpagewithlongscrewclampsortensioningstraps
Checkdiagonals
20x10mmWeldtheprofilesforthebaseplate
Rahemnandsidesweldedcompletely

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Impellermountwithbrakecalipermount

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010
Itisstronglyrecommendedtousediscbrakesasabrakingsystem.
However,itisworthwhileusingalaserpartbecausethepositionfor
thebrakecalipermustfitwellrelativetothehub.
ThelaserpartcanbeorderedwiththeaidoftheDXFfile(!!!must
stillbeintegrated)inalasercuttingoperation.Alternatively,youcan
orderorprintthemonCarlaCargoandtransferthemtoflatsteel.

011
Onthelaserparta4mmdistancefromthebrakecalipermustbeat
therightdistance
Aslaserpartpossibleorfrom20x4mmflatsteel
Thesamepartisalsoneededontheoppositesideoftheimpeller

012
Weldingthewheelmountisbestwhenthesteelframeisliftedtothe
desiredheightof15cm.Bychance,thiscorrespondsexactlytothe
heightofthestandardcrates.
ATTENTION!Payattentiontothecorrectpositionofthebrake
caliper,usuallytheyarenotsoeasilymirrored,sothelaserparts
mustbeturned.

013
Clampthequickreleaseclampwithlaserpartsandplaceitin
positionwithscrewclamps.
Alignandcorrectbyusingtheeye.
Removethewheelsbeforewelding

Stemandcontroltube

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014
20x50mmshortprofilewelding
20x50mmSawofftheprofileprofileswithrelevantangles
20x50mmDrillthepipeprofileatananglewiththehelpofastand
boringmachine
2partsofthesteminfrontofpointsonaflatbase
Preattachanpoints,payattentiontoparallelalignment

015
Lowersupportstrutsatpoints

016
Itisrecommendedtohaveatendencytothesides.
Thesimplestwaytorealizewithroundsteel.

017
Toweldthecontroltubeitiseasiestifthecontroltubeispreparedin
suchawaythatthebearingshellsandtheforktogetherwithimpeller
canbeinstalled.
Whentheframeisreturnedtothestandardboxes,itisrelativelyeasy
todeterminethepositionofthecontroltubeoptimally.
Notetheangle
Measuretheoverrun,whichshouldbeatleast5cmandmaydiffer
dependingonthefork.
Finalweldeverything.

Hubholderonfork

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018
Itmaybeworthwhiletobuildasmallweldinggaugetoavoid
warping.
Itisimportantthattheblackmiddlepartis20x20x2mmprofile

019
Useflattriangles

020
Therearedifferentapproachesforaccommodatingthehub.
Alaseredlaserpartisusedhere.Alternatively,flatsteelcanalsobe
used.Forbestdrillingholesonly,threadthehubandweldit.This
keepsthedistancereallyconstant.
Finally,carefullycuttheslitwiththeFlexandmmslicetogetthe
huboutagain.

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pullrods

024
Pullrodsfrom20x20x1,5mmprofile
Weldasmallstopatoneend.
Leaveitbehindanda6mmholedrillingtotakeupthebalancingbar.

coupling
025
Again,makesurethatitis20x20x2mmprofile.
Generally,anycouplingsystemcanbeused.
TheballheadcouplingfromHebieiswidelyusedinGermanyand
hasalsobeenusedbytheGartencoopformanyyears.
However,ithastobeexpresslypointedouthereagainthattheusual
F1clutchaccordingtodatasheetisonlyapprovedfor40kg!
Theclutchsystemhascertainlyweakened,butseemstobefully
sufficientforthefirsttime,especiallysincetheCarlaCargoconcept
doesnotinvolvetoomuchstressbecausethetensionlinkageisload
free.

Andlet'sgo

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026
Prefabricatedpullrod.
Fordetailsofthesetupsimplytakethephotos.
Bicyclepartsarecommoncomponentsthatyougetineverybike
store.

027
Installthewheels.

028
Andalreadycango.
Thisisthecarlareadytobeusedbymusclepowerorwithanebike.

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Motorization

Theengineisverysimple.Youdonothavetobeanelectronicearthtogetthat.Wehavedevelopedaversionwhichcanusuallyberealizedwith
conventionalcontrollersbysimpleconnectionoftheusualcomponents.

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batterypack
Standardbatteries(lithium...)fromtheebikeindustryhaveproved
theirworth.
36V20A(max)withatleast10Ah

controller
Inprinciple,eachcontrollerisconstructedinasimilarway.
(1)Battery
(2)MotorHALsensors
(3)PASStepsensor
(4)Throttlegrip
(5)Brakeswitch(limitswitch)
(6)Dataprocessing
(7)Programminginterface
(8)Motorphases
(9)3stepswitch
Theconnectionof(1),(2),(3)and(8)isatleastnecessary.
Forexample:36V14A250W
Itisusefultotakeaparameterizablecontrollertosetthefinalspeed
still!!!

motor
ForexampleMXUSXF39/4020inches
Upto1000Wshorttermpeak

Limitswitch
Whentheoverrunbrakeistriggered,theenginesupportistobe
switchedoff.Thiscanbeimplementedviaalimitswitch.
Theswitchusedherecomesfromoldbrakeleversforebikes,where
theseareusuallyinstalled.
However,othersimpleswitchesmayalsobeused.However,an
"opencontact"(opencircuitwhenactuated)mustbeoftype.
Theupperpictureshowstheswitchingstatewhentheoverrunbrake
isactive.Switchopen>nomotorsupportpossible.
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Lowerpictureshowsswitchingstatewithinactiveoverrunbrake.
Switchclosed>Motorsupportpossible.

PASsensor
ThissensorismandatorytodriveinGermanylegally.
WerecommendasimplePASsensorattachedtothebottombracket.
Eachdrivermusthavesuchasensortousethetrailer.
Thisisveryeasytorealizewithaplugconnector.

thanksgiving

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Well,ne.Somewherehatsprobablystarted.TheCarlaCargoideawasbornandtakesitscourse.Countlessprototypes(somebottlesof
beer)andsweatexperimentsarebehindus.Wehadtoputdowndefeatsallthetime.Hereisonlyasmallveryverymodestextract:
OneofourfirsttestexitsattheGartencoopendedwithaweldedseam,Carlabecameindependentandactuallyaholeinatireofa
parkingcartore,(puhhhluckilynopaintdamage).
Ouractualconceptaswehaveitthickandboldonthecrowdfundingpresentedbottomlinesimplyzerofunctioned("ahhtherewe
stoptherenthirdwheel").
Wesufferfromchronicguiltbecausewehavepromisedafter1yearstillsofunnythankgoodnessasshoweringonthe
CarlaCargoSauseorwritingthisguidehere.
OurteamasitwastherenowhadtofinditselffirstandwehadtofindoutifwewantedtoapplytheCarlaCargoideaatallso
thick.
Weessentiallyessentiallyalways(still)underfinancialneedsufferedandveryveryinevitablyhadtobesynonymousinthe
expensiveelectricaldevelopmentsomehowgetthebatteriespaid.
WehadahorrorrideinanancientmotorhomehadtotheInternationalCargoBikeFestivalwhichalmostcertainlyledtothemabe
simplynomorewordatthefestivalthengotoutbecausehehadtoscreamduringtheridesothattheotherscouldunderstand.
Withouttheencouragementofmany,wewouldneverhavebeenthroughitandwouldnotbeatthepointwherewearenow.Thankstoall
whohavealwaysbelievedinandbelieveintheCarlaCargoidea,butinparticular:
Thewholepeoplefromthecrowdfundingwhohavealreadybelievedinusalthoughtheoriginaloriginalconceptwasacomplete
lousy
TheSpaceSushicollectivefromthecarparkSchattenparkerwhichallowedustoallowfirstattemptsatwalkinginthewelding
machine
TheGartencoopFreiburgwhichstillrunswiththeoriginalmotherofallCarla'swhichisarealimpertinence
Ourfirstcustomers,whooftenonlyhadafewpicturesandafewcallsreadytoleafthroughseveralthousandEURforthefirst
CarlaCargoexperiments(withoutyoucouldneverhavemadeanyfurtherdevelopment)
Thegrandfatherforthefactthatwecanstillborrowtheweldingmachine
Thecoinhabitantshadpartlyquiteheavythrough,buteverythingwasfullwithprototypes
Themotherswhosooftenhadtotakecareofthechildrenontheirownintheeveningssowecouldwalkarounddeepintothenight
(anddrinkbeer)
Ourconstructionjoker,whichalwaysthrewitselfaroundthehorizonwithabsolutelyphenomenalflashesoflight
Ourprogrammingstarwhichusuallyonly3hoursbeforethestartofthefairwasreallymotivatedtostartwithprogramming
TheEconautenteamforthefactthatthereareindeedpromotionpots,thesoinclinedideaslikeCarlaCargoalsostillpromote
(knowwhichatallwhattheydothere?)

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Andnowenoughwritten,Iwishyoumuchfunwiththeassembly.Yourmabe)
From"http://werkstattlastenrad.de/index.php?title=Bauanleitung_Carla_Cargo_Crowd&oldid=10828"

Thispagewaslastmodifiedon11January2016,at16:00.
ContentisavailableunderCreativeCommonsAttributionNonCommercialShareAlike3.0UnportedLicense,unlessotherwisestated.

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