Transcript Servicing a controller

Understanding e-Bike Propulsion Systems:
The Controller
Robert Lankin
September 23, 2010
Advanced drive train components
for electric vehicles
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Agenda
• What’s a controller?
• Servicing a controller
• Selling a controller
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What’s a controller?
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Electronic module
Between battery and motor
Regulates motor speed
Prevents excessive currents and overheating
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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
Controller complexity
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Simple DC System
M1
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More Complex System
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More Complex System
Throttle
Brake Switch
Controller
BMS
M1
Bottom
Bracket
Sensor
More Features
More Complex to Troubleshoot
Display
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Agenda
• What’s a controller?
• Servicing a controller
• Selling a controller
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Servicing a controller
1. e-bike doesn’t go at all
2. e-bike doesn’t go as far or fast as it used to
3. e-bike acts or sounds strange
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Servicing a controller
1. e-bike doesn’t go at all
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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
2. e-bike doesn’t go as far or fast as it used to
3. e-bike acts or sounds strange
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Servicing a controller
1. e-bike doesn’t go at all
2. e-bike doesn’t go as far or fast as it used to
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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
3. e-bike acts or sounds strange
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Servicing a controller
1. e-bike doesn’t go at all
2. e-bike doesn’t go as far or fast as it used to
3. 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
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Agenda
• What’s a controller?
• Servicing a controller
• Selling a controller
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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
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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
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