All of the electrical components of an e-bike are connected via a controller. It can control how the bike works in its entirety.
What is an E-bike Controller?
One of the key components of Timewalker e-bike is a controller. It controls every element of the e-bike and functions as its brain. All electrical components, including the battery, motor, throttle, brake, and sensor, must be connected to the controller in order to run the E-bike. You may adjust the motor’s output power, the bicycle’s speed and acceleration, among other things, with the use of a controller.
Because they are exposed to the weather, controllers often arrive in a sealed protective box. Yet, certain designs may be installed inside the frame of the bike and kept out of sight.
The function of the E-Bike Controller?
The controller’s main function is to take inputs from all the E-bike parts like throttle, battery, speed sensor, display, motor, etc., and determine what to be returned signal. The different controller design has multiple protections.
- Low-voltage Protection– The controller monitors the battery voltage continuously, and it shuts down the motor whenever the voltage reaches its cut-off level. It will protect the battery against over-discharge.
- Over-voltage Protection– The controller also monitors the charge level of the battery voltage. It will automatically shut down when the battery voltage reaches its full charge.
- Over-temperature Protection– The controller monitors the temperature of the FET (Field-effective Transistors). It will shut down the motor whenever they become too hot.
- Over-current Protection– If the motor takes more current, the controller reduces the current flow to the motor. It protects the motor windings as well as the FET power transistors.
- Brake Protection– The controller provides more priority to the braking signal as compared to others. For instance, if you apply the brakes and throttle simultaneously, it will perform the brake function.
Types of E-bike Controller
There are three different types of E-bike controllers: BLDC motor controller with hall sensor, brushless DC motor controller, and brushed DC motor controller. See them in more detail.
1. Brushed DC motor controllers
Brushed DC motors come with permanent magnets to go with a connector. The design of these controllers is just a set of keys that can change the current supplied to the engine.
Brushed controllers are mostly used on scooters, electric bicycles, pedelecs, e-bikes,… These controllers are pretty simple to use and are mostly used by DIY hobbyists and enthusiasts.
2. Brushless DC motor controllers
An E-bike, Mostly BLDC motor, and BLDC controllers are used. All of these have permanent magnets and are brushless motors. They provide higher efficiency and are reliable. Generally, everything on the brushless DC motor controllers is simple, including their operation and service.
In the form of structure, it resembles brushed controllers. Brushless controllers come with three phases controlled through a set of keys and at least two transistors (key/MOSFET) per phase. These keys are in the multiple of 6 (like 6, 12, 18, etc.).
3. BLDC controllers for motors with Hall Sensors
In DC motors with brushes, the brushes make contact with the commutator and switch the current to move the rotor. The BLDC motor, however, does not have any brushes. As a result, they require electrical driving via a motor control system.
A Hall Effect Sensor is a transducer based on the principle of Hall Effect. Hall Effect sensors determine the position of the rotor according to the stator. The stator is the fixed part of the motor, whereas the rotor is the rotating part. It also determines the speed and various other attributes required to run a BLDC motor efficiently. These sensors are also known as Rotary encoders that determine the position of the rotor.
