E-Bbike Notes - Wiring, Components & Ratings

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Admin Czar
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E-Bbike Notes - Wiring, Components & Ratings Jan 10, 2024 7:42:29 GMT -7

Quote

Post by Admin Czar on Jan 10, 2024 7:42:29 GMT -7

This is kind of a personal log for notes & links. Finding info & sources for dual hub motor controllers & extension cables has been harder than expected. Plus schematics, wiring & real component ratings are even tougher to find. This first link uses 2 individual controllers instead of one as found on upper end bikes. More here as I do research.

www.ebay.com/itm/404369361582?_trkparms=amclksrc%3DITM%26aid%3D1110025%26algo%3DHOMESPLICE.COMPOSITELISTINGS%26ao%3D1%26asc%3D258816%26meid%3Df1553ffec625451d85d5b5c3ede92301%26pid%3D101506%26rk%3D5%26rkt%3D25%26sd%3D404148225203%26itm%3D404369361582%26pmt%3D1%26noa%3D1%26pg%3D3458402%26algv%3DAlgoIndex5SimRanker&_trksid=p3458402.c101506.m1851

Last Edit: Jan 10, 2024 18:32:38 GMT -7 by Admin Czar

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Admin Czar Administrator Mentally Exhausted & Socially Indifferent Posts: 275	E-Bbike Notes - Wiring, Components & Ratings Jan 10, 2024 7:49:53 GMT -7 Quote Select Post Deselect Post Link to Post Member Give Gift Back to Top Post by Admin Czar on Jan 10, 2024 7:49:53 GMT -7 Dual wheel single controller example www.ebay.com/itm/404148225203?hash=item5e191c84b3:g:FiIAAOSwZuVj4Gr9&_trksid=p5731.m3795
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Admin Czar
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E-Bbike Notes - Wiring, Components & Ratings Jan 10, 2024 8:07:17 GMT -7

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Post by Admin Czar on Jan 10, 2024 8:07:17 GMT -7

SINE WAVE VS SQUARE WAVE (W/MOSFET) CONTOLLER WITH BLUETOOTH

www.ebay.com/itm/163702544456?hash=item261d6e9848:g:n14AAOSw6x9c5j2P&amdata=enc%3AAQAIAAAA0CuXEoQXPgatchmteQEeeyc636ghqN815qA%2FtnrDed7RMmkQE%2BqZs3lbKUMjhAZxw63GODMSBkgsbRiopZ1AbvtwJWS%2FSJgcQXDV1u2cS%2Fjd26JfdshQu06MW0QNK4om71j2pzKLujat%2B7LPjUy5mmrsBF15SkUpMzbUh%2FtLiPh66jXAIwaZqKAH7EToti6qPGhxbsdlCBq7JF5mgQB2N5C8dNnsdGZZLULeIPFLPiUUEctL79mUwU1ozwp4ZBiHnmAlER%2BT18nLGFe0USuSiDE%3D%7Ctkp%3ABk9SR5iLh5meYw

Notice: This Controller work with sensored Brushless DC motor and Kunteng LED LCD Display only
Bluetooth function must work with KT LCD display

6 Mosfet Dual mode Controller Suitable for Brushless Gear Hub Motor 250/300/500W
36V Universal
Dual mode Controller (more stable, high efficiency, low current consumption,long life)
Support LED Control Panel or LCD Control Panel or without any Control Panel (Universal)
Support 36V Light Control

9 Mosfet Sine Wave Controller Suitable for Brushless Non-gear and gear Hub Motor 500/1000W
36V or 48V Universal (support both voltage)
Sine Wave Controller (more stable, high efficiency, low current consumption,long life)
Support LED Control Panel or LCD Control Panel or without any Control Panel (Universal)
Support 36V or 48V Light Control

12 Mosfet Dual mode Controller Suitable for Brushless Non-gear Hub Motor 1000/1500W
48V Universal
Dual mode Controller (more stable, high efficiency, low current consumption,long life)
Support LED Control Panel or LCD Control Panel or without any Control Panel (Universal)
Support 36V or 48V Light Control

18 Mosfet Dual mode Controller Suitable for Brushless Non-gear Hub Motor 1000/1500/2000W
Bluetooth function must work with KT LCD display
48V Universal
Dual mode Controller (more stable, high efficiency, low current consumption,long life)
Support LED Control Panel or LCD Control Panel or without any Control Panel (Universal)
Support 36V or 48V Light Control

model 36V 250/350W 36V 250/350/500W 48V 500/1000W 48V 1000/1500W 48V 1500/2000W
model 6 Mosfet BT 6 Mosfet 9 Mosfet 12 Mosfet 18 Mosfet
Rated voltage DC36V DC36V DC36V/48V DC48V DC48V
Rated current 7A 10A 12A 15A 22A
Low voltage protection DC30±0.5V DC30±0.5V DC30/40±0.5V DC40±0.5V DC40±0.5V
Maximum current 15±1A 20±1A 25±1A 30±1A 45±1A
Speed set 1-4.2V 1-4.2V 1-4.2V 1-4.2V 1-4.2V
Brake input Low-level Low-level Low-level Low-level Low-level
size 100*61*35mm 100*61*35mm 125*66*42mm 176*82*41mm 240*82*41mm

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Admin Czar
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E-Bbike Notes - Wiring, Components & Ratings Jan 10, 2024 12:58:31 GMT -7

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Post by Admin Czar on Jan 10, 2024 12:58:31 GMT -7

^{MOSFET Review – Structure, working principle: - www.electricalclassroom.com/mosfet-symbol-working-structure/}

^{DYI Example: MOSFET Motor Control Circuit - www.instructables.com/DIY-MOSFET-Motor-Controller/}

Now it is time to use your new motor controller. If you have designed and built it like I have than this should be easier and you can just follow the layout above. If you have placed your pieces differently or soldered the circuit together differently than just look at the schematics layout above. Either way make sure you look at the schematics diagram above.

Setup With a Micro-controller:

Plug or connect your motor to the motor pins on your motor controller.
Insert the motor controller into a breadboard.
Using two colored wires connect the Vin to your micro-controllers Vin pin And the GND to the GND pin.
Using two more colored wires connect the speed and reverse to two digital pins of your choice.
Now just program away.

Safety:

Make sure that you do not exceed 30 volts at Vin.
Do not mix up the pins.
If you decide to go over 15 volts connect the Vin and GND directly to the source and connect the Ground to the Micro-controllers GND.
When working with more power try attaching a heat sink to the MOSFETs.
Only use DC two wire motors.

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E-Bbike Notes - Wiring, Components & Ratings Jan 10, 2024 20:26:02 GMT -7

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Post by Admin Czar on Jan 10, 2024 20:26:02 GMT -7

It's funny. As I read this stuff, much of it is overly complex for a normal bike rider. Tesla & other car mfg with auto-drive features are having the Feds deem the feature "design flaws" for not anticipating the human user wont read or heed the instructions for use. It's costing them million in recalls because the Fed says everything must be stoopid-proof. Remember, 50% of the population has an IQ of 99 or lower (as evidenced by the two main presidential candidates).

The point is, the more complex motor controllers found on high end ebikes are built with the expectation that the pedals will be used solely as a place to rest your feet. The reality is these bikes will be used like motorcycles with some able to reach 60 mph or more. More laws will be passed as cars will be running over these tooth picks on two wheels leaving the rider to be scraped off the road with french fry scoopers. But with built-in brake lights, turn signals, motor throttle cutoffs, sonic obstruction sensors etc, the manufacture/distributor can try to defer liability. But, no matter what you do, you can't defer stoopid.

What we have now are companies taking the equivalent of a $100 walmart Roadmaster, sticking a motor & battery on it, calling it "green" & selling it (for $400- $500) to people that cant even fix a flat bike tire. How ya spoze thats gonna work out? I see a lot of spare parts for me to pilfer in the near future!

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lurker Senior Member Posts: 2,363 Member is Online	E-Bbike Notes - Wiring, Components & Ratings Jan 11, 2024 12:59:55 GMT -7 Quote Select Post Deselect Post Link to Post Member Give Gift Back to Top Post by lurker on Jan 11, 2024 12:59:55 GMT -7 re posts 1-4; in computer programming we used to have a term for flowcharts that looked like that, (B)owl of (S)paghetti. post 5, yes, agree.

Admin Czar
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E-Bbike Notes - Wiring, Components & Ratings Jan 11, 2024 16:22:52 GMT -7

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Post by Admin Czar on Jan 11, 2024 16:22:52 GMT -7

Jan 11, 2024 12:59:55 GMT -7 lurker said:

re posts 1-4; in computer programming we used to have a term for flowcharts that looked like that, (B)owl of (S)paghetti.
post 5,

Yes indeed. I may end up building a controller. Most production units are only rated to 112' max & depend of heat dissipation alone (no fan). Components are out there rated to 158'F. I don't think it's beyond my capabilities to build a controller but not done figuring out MOSFET power step circuits (or eliminate them) & if the hall effect sensors inputs are required if Im not pre-programming a max speed or cruise control.

I might also find an industrial DC controller but they're not really made with energy efficiency or li-po batteries in mind.

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lurker
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E-Bbike Notes - Wiring, Components & Ratings Jan 11, 2024 16:42:16 GMT -7

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Post by lurker on Jan 11, 2024 16:42:16 GMT -7

for me "pedal-assist" means i pedal occasionally when the e-stuff needs help, like up steep hills. i generally cruise the back streets at <= 20mph which is what my bike is rated for. to go faster or farther, i have an actual street-legal motorcycle which cost me, broken-in, 4k which is less than some e-bikes. the technology is intriguing, and shows promise but i don't really think it's ready for any but early-adopters like us.

Last Edit: Jan 11, 2024 16:49:09 GMT -7 by lurker

Admin Czar
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E-Bbike Notes - Wiring, Components & Ratings Jan 11, 2024 17:10:46 GMT -7

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Post by Admin Czar on Jan 11, 2024 17:10:46 GMT -7

Yeah there's hall effect sensors at the pedals for the assist function but many of the motors (not all) have an HE output to the controller. I don't think a MOSFET will work properly without the hub motor input, or will it work at all? Or if the controller type expects to see that input but it's not present, what happens? i.e. does the pedal assist work but not the speedometer, odometer, etc. I don't look forward to decrypting a reply to those questions from a chinese engineer. They can't even pay someone to write comprehensible amazon & ebay adds. Tech talk may be impossible. And while they're great at engineering this stuff, there is no standard so each product is different based on which plant it comes out of. Even the wire termination & plugs differ between units.

BTW that 20-21 mph limit can be disabled. Most bikes sold in the US have that imposed controller limitation.

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