This was presented to the audience at Recumbent Cycle Con.

1. Falco Electric Assist
Options
Recumbent Cycle-con 2019

2. AGENDA
Insuring Safety for Falco
assisted riders;
Safe Installation Practices for
All Trike Brands;
Electric Bike Technology
Comparisons;

3. FALCO EBIKE COMPONENTS
Quick Introduction

4. SYSTEMS AND CONFIGURATIONS
• One Motor;
• Five Batteries;
• Two Consoles;
• Apps.
Li1
Li3
Li7
Li9
Li11

5. SYSTEMS AND CONFIGURATIONS
• One Motor;
• Five Batteries;
• Two Consoles;
• Apps.
Wired Plus Minus
WPM-AIO
Wireless Console
Falco Flash Apps
Li11

6. FIVE
SYSTEMS

7. Range
Speed/Power
Lighter Price
10
10 10
10
0
f7.7, f7.9, f7.11
(48V Systems)
70+ Mile Range
Peak Power of 750W
Price Range $2095 - $2295
e5.1, e5.3
(36V Systems)
40+ Mile Range
Peak Power of 500W
Price Range of $1695 - $1895

8. THE MOTOR
Hx Motor

9. HX PLATFORM

10. 11-Speed

11. SPEED, POWER AND TORQUE
• 15/25, 20/32 and 28/45 mph/kph Speed Limits;
• 750W Max Power Output;
• 45Nm Max Torque;
11

12. WHEEL SIZES
• 16” and Up;
• Wheels hand built in the USA;
• Use Velocity Rims – Cliff Hanger, Aero Heat etc.
12

13. DROP-OUTS AND SPOKE HOLE
COUNTS
• Standard Configuration:
• Vertical;
• 135mm;
• 32 Spoke Holes;
• Non-Standard Configurations:
• 145mm, 160mm, 170mm, & 190mm;
• 36, 40, 48 Spoke Holes.
13

14. COMPATIBILITY
• 11-Speed Cassette Compatible;
• Disc Brake Compatible;
• 36V or 48V Batteries.
14

15. BATTERIES
October 11, 2019

16. BATTERY SPECS
Li1, Li3 Li11 Li7, Li9
Voltage 36V 48V 48V
Amp-Hours 11.6 Ah 10.5 Ah 14 Ah
Peak Discharge Current
(30s)
30A 30A 30A
Peak Power Draw(30s) 1000W 1400W 1400W
Watt-Hours 400 Wh 500 Wh 672 Wh
Storage Temperature -20oC to 35oC (-4oF to 95oF
Cycle Life > 500 Cycles
Type Of Cells Samsung SDI INR18650-35E/Sanyo (Panasonic) NCR18650PF

17. LI1 AND LI11 BATTERIES
State of Charge Indicator (Push Square Button to Activate)
• Full Charge is 3 Green and 1 Red LED
• 75% Charge is 2 Green and 1 Red LED
• 50% Charge is 1 Green and 1 Red LED
• 25% Charge is 0 Green and 1 Red LED
Charger Hook Up

18. LI1 AND LI11 BATTERY DIMENSIONS
1-11/16”
42.9 mm
5-53/64”
148 mm
2-3/16”
55.6 mm
12-5/8”
320.6 mm

19. LI1 AND LI11 BATTERIES
ON/OFF Switch
• Red Light indicates Battery ON

20. LI1 AND LI11 BATTERIES
15A Dual Automotive Fuse
Battery Output
+ve-ve

21. LI1 AND LI11 BATTERIES
Battery Voltage and Capacity
Battery Serial Number

22. BATTERY HOLDER
9-1/2”
241 mm
5 -13/16”
147.6 mm
2-5/32”
54.8 mm

23. BATTERY HOLDER
Battery Holder
Key Lock for the Battery
Keys
Power Cable

24. BATTERY HOLDER14.5cm (5-11/16”)
18” Long Power Cable
M6 Bolts (4x)

25. BATTERY HOLDER
7 Self-
Threading
Screws

26. BATTERY IN THE HOLDER
13 – ½”
343 mm

27. EXAMPLES OF INSTALLATION

28. EXAMPLES OF INSTALLATION

29. LI3 BATTERY
13 ½”
343 mm
4 1/8”
105 mm

30. LI3 BATTERY
3-35/64” Round
90.1mm

31. LI 3 BATTERY
11-1/4”
285mm
Charger Hook Up

32. LI3 BATTERY
State of Charge Indicator (Push Square Button to Activate)
• Full Charge is 3 Green and 1 Red LED
• 75% Charge is 2 Green and 1 Red LED
• 50% Charge is 1 Green and 1 Red LED
• 25% Charge is 0 Green and 1 Red LED

33. LI3 BATTERY
Battery ON/OFF Switch
(Red Light Indicates Battery ON)
Battery Gauge Switch
Hole for Key Lock

34. LI3 BATTERY
Fuse
2 15A Automotive Fuses
Battery Output

35. LI3 BATTERY
Keys
Battery Holder
Power Cable (18”)
2” Slots

36. EXAMPLES OF INSTALLATION

41. LI7 BATTERY
ON/OFF Switch
Keys

42. LI7 BATTERY
Battery Gauge Switch
Power Cable (18”)
Battery Gauge
USB Charging Port
5-31/64”
13 – ¾”
3-15/64”

43. LI7 BATTERY
Power Cable (18”)
1-3/4”

44. LI7 BATTERY
Power Connector

45. LI7 BATTERY
Charge Status Indicator
State of Charge Indicator (Push
Square Button to Activate)
• Full Charge is 3 Green/Red and 1
Red LED
• 75% Charge is 2 Green/Red and 1
Red LED
• 50% Charge is 1 Green/Red and 1
Red LED
• 25% Charge is 0 Green and 1 Red
LED

46. LI7 BATTERY
Pull Up Tab for easy
removal of the battery

48. INSTALLATION EXAMPLES

58. LI9 BATTERY
Keys
Power Cable
ON/OFF Switch

59. LI9 BATTERY
Charge Status
Indicator
3-25/32”

60. LI9 BATTERY
On Off Switch
Metal Reinforcement

61. LI9 BATTERY
Optional Bottom Pads

66. CONSOLE OPERATION
World’s 1st Wireless eBike Console
Main Functions:
• Change Assist Levels;
• Show Speed;
• Show Trip Mileage;
• Show Battery Voltage;
• Set Wheel Circumference.

67. CONSOLE OPERATION
World’s 1st Wireless eBike Console
Wireless Console Connectivity:
• Based on ANT+ Wireless Technology
• It can pair automatically at Power ON;
• Use the Mode button to pair;

68. CONSOLE
USB Charging Cable
Wireless Console
Plus Minus Controls
Three Main Components

69. CONSOLE ON/OFF
Console ON/OFF is provided to
conserve the console battery

70. FALCO SMART PHONE
TECHNOLOGY

71. FALCO FLASH BLE 4.0 APP
• Total of 6 Screens;

72. MAIN
SCREEN

73. EDRIVE
DATA
SCREEN

74. ADJUSTABLE
SPEED SCREEN

75. TORQUE
SENSOR
SETTINGS
SCREEN

76. TORQUE SENSOR
DIAGNOSTICS
SCREEN

77. ASSIST LEVEL
CUSTOMIZATION

78. OPERATING THE APP

79. SETTINGS

80. ACCESS TO
7
SETTINGS

81. CRM
SETTINGS

82. SENSOR
SELECTION
SETTING

83. WIRED
PLUS
MINUS –
ALL IN
ONE

84. HOOK UP
• Hook up at the other end of the
wireless module;
• Can also be hooked up directly to the
motor
Wireless
Module

85. LEVELS

86. OPERATION
• Clicks on the +VE
• Single Click
• Quick Double Clicks
• Quick Triple Clicks
• Clicks on the –VE
• Single Click
• Quick Double Clicks
• Quick Triple Clicks
• Hold the +VE
• Hold the -VE

87. THE
JUNCTION
BOX

88. JUNCTION BOX OPERATION
• Obviate the need to charge the console;
• Access to Separate Break Sensor Input;
• Access to Separate Throttle Input.

89. INSURING SAFETY
Falco Assisted Riders

90. MOTOR INSTALLATION
• Wheel Hardware
Motor Axle
12 mm Diameter
10 mm Flats
1mm Fine Thread
Chromoly Hardened Steel

91. WHEEL HARDWARE
Left Right
M12

92. TORQUE
ARMS
Can be installed on either
side
Base
Arm 1
Arm 2

93. TORQUEARM
INSTALLATION M6 BoltM5 Bolt
M6 Lock Nut
Torque
Bar
M12
2 Washers
(2mm)
Torque Arm
Base
Torque Arm 1

94. TORQUEARM
INSTALLATION
Torque to 40 Nm.
OK to use blue Loctite 242 on the
Axle threads.

95. DO WE NEED A SECOND SET OF
TORQUE ARMS?
Second set of torque arms is not required.

96. DROP-OUTS
• Good Drop-Outs
12mm
Deep

97. GUIDELINES FOR ALL TRIKE BRANDS
• Use Torque Arm for All Aluminum Frames i.e., HP, Catrike, Ice, etc.
• Torque arms are not required for Chromoly Frames.

98. ELECTRIC BIKE
TECHNOLOGY
COMPARISONS
The Battle of Two Drives

99. OUR STRENGTHThrottle
Speed Sensor
Torque
Sensor
Customization
10
10 10
10
0
Falco
Bosch, Brose, Shimano
Bafang

100. OUR STRENGTHHill Climbing
Range
Price Speed
10
10 10
10
0
Mid-Drives
Falco Direct Drive

101. OUR STRENGTHStability
Portability
Comfort Speed
10
10 10
10
0
Falco

102. ARE MID DRIVES STABLE FOR
TADPOLE TRIKES?
• How and Who will answer that question?
• Why mid-drives have been made popular for
mountain bikes?
• Same rules don’t apply in the Trike World?

103. MID-DRIVES
BLIND LEADING THE BLIND
Why Mid-Drives will not last in the bicycle industry?

104. MID-DRIVE ISSUES
• Expensive;
• Highly Complex;
• High Maintenance Cost;
• Unreliable;
• Limited Lifetime.

105. THE BATTLE
Mid Drives
Direct Drives
The Secret
Weapon

106. WHY MID-DRIVES BECAME A
SOLUTION?
2011
Mid-Drives
produced
30Nm of
Torque
Panasonic
Daum
Etc.
No Issues with
Existing Bicycle
Components
40 to 90 Nm Journey
2018
Re-Engineered of Bicycle
Components
Commitment to a Wrong Solution
Continues
Expensive, Wasteful and Unreliable
DemiseofBionXandGoSwissDrive
Industry Wide
Commitment
to Mid-Drives
Continues
2021
BeginningofDeclineofMid-Drives

107. BROSE
Motor
1st Gear Stage
2nd Gear Stage
Control Electronics

108. BOSCH
Two Gear Stages

109. ISSUES WITH MID DRIVES
0.00
0.20
0.40
0.60
0.80
1.00
1.20
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0 2000 4000 6000 8000 10000 12000 14000
ProbabilityDistributionofFailure
PopulationDistributionofFailure
Number of Miles
Mid Drive Mechanical Failure Distribution (Major Brand)
Mean Failure Point ~ 4000 Miles
Standard Deviation ~ 2500 Miles
Probability of Failure
Failure Population Distribution
Data Sources:
https://electricbikereview.com/forum/forums/
https://pedelecmonitor.wordpress.com/

110. BICYCLE GEAR EFFICIENCIES
Each transmission at
three loads: 80 watts,
150 watts, and 200
watts, all at 75 rpm.
"The mechanical efficiency of bicycle derailleur and hub-gear
transmissions" (PDF).
http://www.ihpva.org/HParchive/PDF/hp52-2001.pdf

111. BICYCLE GEAR EFFICIENCIES
Each transmission at
three loads: 80 watts,
150 watts, and 200
watts, all at 75 rpm.
"The mechanical efficiency of bicycle derailleur and hub-gear
transmissions" (PDF).
http://www.ihpva.org/HParchive/PDF/hp52-2001.pdf
88 to 93%
90 to 95%

112. Rider Force F1 (N)
d2
d1
d3
𝑇 =
2𝐹1 𝐿
𝑑1
𝐹𝑡𝑖𝑟𝑒 =
𝑇𝑑2
𝑑3
Ftire

113. POWER TRANSMISSION
An average tadpole recumbent rider can
generate a force of 50 to 100N at the
pedals
A mid-drive motor can
increase the chain
tension 10 times

114. POWER TRANSMISSION EFFICIENCY
(MID DRIVE)
Mid-Drive
Motor
85 to 95%
1st Stage
Gear
Battery
80 to 90%
2nd Stage
Gear
85 to 95%
Derailleur
85 to 95%
Wheel
85 to 95%
Lowest Efficiency = 42%
Highest Efficiency = 73%
Efficiency Deteriorates Over Time

115. POWER TRANSMISSION EFFICIENCY
(DIRECT DRIVE)
Direct-
Drive
Motor
85 to 95%
Battery
80 to 90%
Wheel
Lowest Efficiency = 68%
Highest Efficiency = 85%

116. POWER TRANSMISSION EFFICIENCY
(GEARED DIRECT DRIVE MOTORS)
Geared
Direct-
Drive
Motor
85 to 95%
Gear
Stage
Battery
80 to 90%
85 to 95%
Wheel
Lowest Efficiency = 57%
Highest Efficiency = 81%
Efficiency Deteriorates Over Time

117. TORQUE TRANSMISSION
Mid-Drive
Motor
1st Stage
Gear
Battery
2nd Stage
Gear
Derailleur
Wheel
1 to 5 Nm Motor
12 to 18 times Multiplier
1.2 Times Normally.
Upto 3 times with very
small front chain ring
Torque at the Wheel can be increased to
270Nm with very small Front Chain ring
(Cheating!)