Project Owner: Graham

Project Ultrabike: The beginnings

Started: October 2006
Completed: Get back to you on this...

Well enough arm twisting from Paul, so here is a long awaited update on my electric bicycle (in the making). Basically the project was started in late 2006 and, as with most endevours, has ended up taking considerably more time than originally anticipated.

The controller has been designed from the ground up and has been engineered with vehicles more substantial than an electric bicycle in mind. For this reason, every standard feature for a vehicle has been incorporated into the controller, though they are unlikely to be used for the given target bicycle. The overall idea is to evolve the controller once this first objective has been achieved. The following features have been incorporated into the design:

1. A (high efficiency) step-down DC/DC converter to regulate (40V to 95V) down to 12.5V 5A Output max.

2. Indicators, break light, headlight and tail-light outputs.

3. Backlit (4 line x 20 character) LCD display that displays speed, mileage, battery status etc.

4. Full microprocessor control of speed and motor torque for 2 independent Brushless DC motors.

5. Full protection against excessive battery discharge, motor overload and controller temperature etc.

Briefly, the following specification applies to the controller:

1. Nominal battery voltage = 72V DC

2. Rated continuous output current per motor = 20A

3. Burst current per motor = 40A (thermally modelled by the controller to protect the motor and associated wiring)

4. Rated power per motor = 1.2kW (1.6hp)

5. Fully protected against overload, reverse polarity, over temperature etc.

6. 3 Phase MOSFET drive (under microprocessor control) for each of the 2 DC brushless motors

The controller is being designed (note present tense...) to be fully protected in addition to ensuring driver safety while operating, even in the unlikely event of controller failure whilst driving at speed. This is an issue not really addressed by many other controllers of brushless DC motors which have the potential to lock the wheel up in the event of a catastrophic failure or battery disconnection.

Well, more is to be added later but in the mean time, see the video below of a test run when operating at 72V DC. Oh, and feel free to contact me with any comments or enquiries, I'm always interested to here peoples responses to this eco-friendly, inflated oil price beating project.

Prototype Electric Bike Completion
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Electric bike controller At 2008-10-18 16:00:27 From karmaReply To This Post
love the display, if there ever for sale ill buy one :)

Electric bike controller At 2008-12-19 08:45:18 From GrahamReply To This Post
Thanks, but this unit is a prototype. I am however continuing with the development of its successor which will be a more industrialised unit. IE it will be a more finished product and be more easily produced in quantities greater than one!! Keep a lookout, though it will take me some time to get this unit running, as I will be posting ongoing updates on this new and exciting development.

Electric bike controller At 2009-02-04 20:20:16 From TonyReply To This Post
Hey I'm actually very much interested in BLDC motors, especially hub motors. I'm planning a research project in which I will use a micro controller to control a BLDC motor, also with intentions of being implemented in an automobile. What are the specs on the hub motor you are using? Have you tested it regenerative properties?

Electric bike controller At 2019-07-11 03:20:58 From Evyatar Aviel Cohen ZadaReply To This Post
This reverse function can be used like a break motor instead or if the brakes are going bad?

Re: Electric bike controller At 2019-09-05 18:56:09 From GrahamReply To This Post
Yep, it certainly can. It's referred to as regenerative breaking. As long as you have headroom in your energy storage, you can regenerate energy back into your batteries instead of hitting the brakes. Saves wear and tear and conserves energy useage.

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