12/4/2016 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

1 20x20x1.5mm 90 90 1625mm 4
2 20x20x1.5mm 90 90 150mm 4
3 20x20x1.5mm 90 90 110mm 6
4 20x20x1.5mm 60 60 152.5mm 6
5 20x20x1.5mm 60 72.5 1400mm 2
6 20x20x1.5mm 55 72.5 230.1mm 2
7 20x20x1.5mm 90 90 112mm 4
8th 20x20x1.5mm 60 90 53.8mm 4
9 20x20x1.5mm 60 90 53.8mm 4
10 20x20x1.5mm 90 90 610mm 4
11 20x10x1.5mm 90 90 610mm 5
10 20x50x1.5mm 90 90 110mm 1
11 20x50x1.5mm 90 90 400mm 1
12 20x50x1.5mm 90 90 200mm 1
13 20x50x1.5mm 90 90 200mm 1

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Commonlyusedsteelcrosssections.

Crankshaftlinkage

position crosssection Angleleft Angleright length number

1 20x20x1.5mm 30 30 150mm 2
2 20x20x1.5mm 15 45 150mm 2
3 20x20x2mm 90 90 100mm 1
4 20x20x2mm 90 90 150mm 1
4 15x15x1.5mm 90 90 850mm 1
5 15x15x1.5mm 90 90 30mm 1

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)

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