MotoCzysz announcement prompts need for new TTXGP rule

March 3, 2010

Following a recent announcement from Michael Czysz’s company, MotoCzysz, I recently added a new rule to the TTXGP Technical Rules Wiki.

From the announcement:

The MotoCzysz LQ (liquid cooled) IPM (internal permanent magnet) 75kW/100hp electric motor is one of the highest torque/density motors in the industry (250+ft/lbs/340+Nm continuous 77lbs/35kg).  The IPM solution generates more torque while being more efficient than any comparably sized AC induction motor.  The MotoCzysz patent pending cooling system elevates the motor’s nominal power output closer to the motor’s peak power output.

Later, in the specifications, I noticed this:

Voltage                                    240V+
Power                                      75kW/100hp (continuous)
Weight                                     77lbs/35kg (complete with pump and plates/mounts)
Diameter                                  254mm/10″
Width                                       190mm/7.5″
Cooling                                    liquid (oil)
Efficiency                                  93% (under continuous load at 2X 70c operating temp)

Oil (and, to some extent, water, if contains certain additives) poses a hazard to motorcycle racers if it is deposited on the track surface.  That hazard is increased exponentially if the oil is spewing from a source on your bike directly in line with your rear tire.  Because of the extreme speeds and resulting extreme vibrations involved in motorcycle racing, items like oil plugs can vibrate loose.  This hazard can be remedied by requiring teams to “safety-wire” these fittings.

Safety-wiring an oil plug, via Sport Rider magazine (sportrider.com)

From Sport Rider magazine:

Racers use safety wire for two reasons. First, safety wire provides positive locking on fasteners, preventing them from backing out. Second, safety-wired fasteners allow mechanics-and tech inspectors-to visually ascertain that key components have been tightened. This oil drain plug is a prime example. The bolt has been drilled with multiple holes to simplify the wiring process. The wire is run through a pair of holes and twisted to the approximate length needed to reach a hole drilled in one of the case’s flanges. (Note: While safety-wire pliers are not required, they make the job much easier.) Proper safety-wire technique (1a) dictates that the bolt be wired so if it starts to back out the twisted wire prevents it from doing so. Novices often forget this simple fact.

The article quoted contains more great pictures and tips on how to proceed with safety-wiring your bike.

The language I added to the TTXGP Technical Rules:

Fluid-based Coolant Systems

All water-cooled PTWs must use water ONLY and safety-wire all drain plugs, radiator caps, and petcocks. Antifreeze may NOT be used in the cooling system. Use of the Red Line Brand “Water WetterTM” or similar coolant additive is allowed.

All oil-cooled PTWs must safety-wire all drain plugs, radiator caps, and petcocks.

Can you think of other connectors or fasteners on an electric motorcycle that would need to be safety-wired?  Either respond in the comments, below, or go forth and add to the Wiki.



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