Leaf spline coupler

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EVwhisperer
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Re: Leaf spline coupler

Post by EVwhisperer »

Newbie here.
Any update on coupler price/availability? Or is it just the drawings you're offering?
I ordered a couple clutch discs, but want to try this route as well. I have an EM57 stack and soon a steel mounting plate.
Thanks.
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Bratitude
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Re: Leaf spline coupler

Post by Bratitude »

EVwhisperer wrote: Tue Jan 19, 2021 8:25 pm Newbie here.
Any update on coupler price/availability? Or is it just the drawings you're offering?
I ordered a couple clutch discs, but want to try this route as well. I have an EM57 stack and soon a steel mounting plate.
Thanks.
take a look at the first post.

made a batch. But I’m sold out now.

looking at changing and simplify the design to make the coupler cheaper.
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Re: Leaf spline coupler

Post by vwbrady »

since i used your CAD to get my Leaf splines, you're more than welcome to sell the universal shaft i made.
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Re: Leaf spline coupler

Post by mdrobnak »

Stupid question, but the splines on a EM61 are the same as the EM57, or are they different? I realized the wiring might be easier for the EM61 - I'm not sure how one would seal up the area on the EM57 given it's designed to be under the inverter.

I know it says untested, but do we know if it is the same, or does someone have a wiring solution for the EM57?

-Matt
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Re: Leaf spline coupler

Post by Bratitude »

mdrobnak wrote: Tue Mar 23, 2021 5:25 pm Stupid question, but the splines on a EM61 are the same as the EM57, or are they different? I realized the wiring might be easier for the EM61 - I'm not sure how one would seal up the area on the EM57 given it's designed to be under the inverter.

I know it says untested, but do we know if it is the same, or does someone have a wiring solution for the EM57?

-Matt

I’m pretty dam sure they are the same. But yes, like ya said, untested.

em61 wiring is definitely much nicer if space is tight. and (might just be bs internet speculation) that the em61 is the better motor, more over built and capable as it is very close to the rd units. Can’t remember where I heard this discussion.

The matting faces and seal on the em57 are quite simple. 3D printing a cable gland/seal that matches the em61, wouldn’t be hard to design.

I’ve done one for the dc hv lines, one for the phase connections wouldn’t be much different.
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Re: Leaf spline coupler

Post by mdrobnak »

Ok, I'll be the guinea pig. Even if I put in the crazy motor that I was going to later, I'm going to start off with the Leaf motor to at least validate the rest of my system design.

-Matt
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Re: Leaf spline coupler

Post by vwbrady »

EM57 and 61 splines are exactly the same.

mdrobnak, I'm with you in that sealing the inverter DC input is difficult, but i know i've seen someone on the forum who 3-d printed something for that purpose.
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Re: Leaf spline coupler

Post by Bratitude »

vwbrady wrote: Fri Mar 26, 2021 1:54 pm EM57 and 61 splines are exactly the same.
have you tested this? how sure are you? this is great news
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Re: Leaf spline coupler

Post by vwbrady »

it fits perfect. i might have a video. let me check.

I can't believe i even took this! haha

https://photos.app.goo.gl/KP5fcVHcSRxDvXQx6
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Re: Leaf spline coupler

Post by Bratitude »

vwbrady wrote: Mon Apr 05, 2021 8:43 pm it fits perfect. i might have a video. let me check.

I can't believe i even took this! haha

https://photos.app.goo.gl/KP5fcVHcSRxDvXQx6

looks like a em57 motor in your video. which yes I spent an enormous amount of time making sure it fit correctly. But would like to know if it fits the em61 motor.
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Re: Leaf spline coupler

Post by Traju »

Any update on availability?
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Re: Leaf spline coupler

Post by Bratitude »

should have newer, cheaper coupler available in 2 months
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Re: Leaf spline coupler

Post by Bratitude »

hey folks, after lots of back and forth with the machine shop, v2 couplers are finally in production!

-4140 alloy steel
-simpler design. No flange, but still compatible with the bearing.
-cheaper!
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Re: Leaf spline coupler

Post by Bratitude »

v2 couplers arrived !

EDM machined 4140 goodness
F6CF74C2-C0A5-4850-B35B-E3916A8784DA.jpeg
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Re: Leaf spline coupler

Post by JaniK »

Looks nice and simple enough.

What kind of price is cheaper? :)
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Re: Leaf spline coupler

Post by vwbrady »

what does the other side look like?
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Re: Leaf spline coupler

Post by arturk »

I would be interested in getting one or two. Please let us know the price. Thanks!
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Re: Leaf spline coupler

Post by Bratitude »

vwbrady wrote: Sat Jun 26, 2021 5:09 pm what does the other side look like?
347FEF55-AD00-4FE7-822F-08EFF84393E9.jpeg
I’ll post drawings and better photos once I’m back at the shop. About a week from now


arturk wrote: Sat Jun 26, 2021 10:11 pm I would be interested in getting one or two. Please let us know the price. Thanks!

JaniK wrote: Sat Jun 26, 2021 4:40 pm Looks nice and simple enough.

What kind of price is cheaper? :)
260$ Canadian!
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Re: Leaf spline coupler

Post by vwbrady »

looks like you simplified it the same way i did. though i didn't see any need for a bearing. just a universal opposite side to add a clutch spline piece to.

viewtopic.php?p=23018#p23018
PXL_20210403_025616976.NIGHT.jpg
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Re: Leaf spline coupler

Post by Bratitude »

vwbrady wrote: Mon Jun 28, 2021 4:27 pm looks like you simplified it the same way i did. though i didn't see any need for a bearing. just a universal opposite side to add a clutch spline piece to.

viewtopic.php?p=23018#p23018

PXL_20210403_025616976.NIGHT.jpg

still compatible with the bearing, now just some additional machining if some one wants a flywheel or Drive shaft interfaced compared to gearbox direct drive
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Re: Leaf spline coupler

Post by vwbrady »

It's a great price! as now to get mine made again, it's about $500 through 3d hubs.
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Re: Leaf spline coupler

Post by JaniK »

Very interesting, price is good too. I will try first to use the Leaf box, but if or doesn't fit good, here is the plan B then.
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Re: Leaf spline coupler

Post by raine »

Hi. Do you have these couplers available at hand? I am interested buying one and having it shipped to Finland.
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Re: Leaf spline coupler

Post by Bratitude »

raine wrote: Wed Jun 30, 2021 9:01 pm Hi. Do you have these couplers available at hand? I am interested buying one and having it shipped to Finland.

Yes, back at the shop in a few days then I can ship them out. PM me
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Re: Leaf spline coupler

Post by Bratitude »

0010-000-004_R00_LEAF_COUPLER.JPG
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