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Understanding e-Bike Propulsion Systems: The Controller Robert Lankin September 23, 2010. Advanced drive train components for electric vehicles. Agenda. What’s a controller? Servicing a controller Selling a controller. What’s a controller?. Electronic module Between battery and motor

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Understanding e-Bike Propulsion Systems:

The Controller

Robert Lankin

September 23, 2010

Advanced drive train components

for electric vehicles


Agenda

  • What’s a controller?

  • Servicing a controller

  • Selling a controller


What’s a controller?

  • Electronic module

  • Between battery and motor

  • Regulates motor speed

  • Prevents excessive currents and overheating


Controller complexity

  • Simplest: on/off switch for DC motor

  • Variable speed DC motor + twist throttle

  • Brushless motor with hall sensors

  • Brushless motor without hall sensors

  • Pedelec torque sensor

  • Smart communication with battery

  • Smart communication with display

  • Built in diagnostics and programming

Increasing Complexity


Simple DC System

M1


More Complex System


More Complex System

Throttle

Brake Switch

BMS

Controller

More Features

More Complex to Troubleshoot

Bottom

Bracket

Sensor

M1

Display


Agenda

  • What’s a controller?

  • Servicing a controller

  • Selling a controller


Servicing a controller

  • e-bike doesn’t go at all

  • e-bike doesn’t go as far or fast as it used to

  • e-bike acts or sounds strange


Servicing a controller

  • e-bike doesn’t go at all

    • Check power to controller (battery, fuse, switch, wiring)

    • Burnt smell?

    • Check controller LED for error codes (read manual!)

    • Check throttle and brake signals at controller

    • Check motor hall signals (wet?)

    • Spin hub motor backwards, check for AC voltages – zero voltage means failed wiring somewhere

  • e-bike doesn’t go as far or fast as it used to

  • e-bike acts or sounds strange


Servicing a controller

  • e-bike doesn’t go at all

  • e-bike doesn’t go as far or fast as it used to

    • Weak battery or defective charger

    • Low tire pressure

    • Mechanical friction (bearings, alignment, brakes)

    • Intermittent operation may be overheating due to loads, friction, or defective temperature sensor

  • e-bike acts or sounds strange


Servicing a controller

  • e-bike doesn’t go at all

  • e-bike doesn’t go as far or fast as it used to

  • e-bike acts or sounds strange

    • Pulsations or dead zones may be bad hall sensor, wet hall sensor, or hall sensor wiring problem

    • Erratic forward motion may be faulty or lose connectors

    • Conversion kits may have mechanical fatigue in axle, spokes, rear sprocket


Agenda

  • What’s a controller?

  • Servicing a controller

  • Selling a controller


Selling a controller

  • Power rating (250W vs. 500W vs. 750W)

    • Hill climbing, acceleration, head wind, loads

    • Compare bikes, compare routes

  • Voltage rating (24V vs. 36V vs. 48V)

    • Higher voltage typically with higher power

  • Throttle vs. pedelec

    • Inexperienced vs. experienced riders

  • Feel: smooth and intuitive vs. hesitations

    • Ride and compare different systems


Selling a controller

  • Features

    • Sensorless – fewer service issues, but may need a running start

    • Regenerative braking – improved range, perhaps improved braking feel

    • Reliability, durability, weather resistance

    • Integrated diagnostics


LEVA Thanks our 2010 Interbike Sponsors!


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