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Electric Bicycle Controller Improved Method Jun 27, 2017

Electric Bicycle Controller Improved method 

Improved method editing

Electric vehicle controller should take into account the actual use of the battery and the motor to be fully designed, should fully consider the battery, controller, motor relationship between the three, as a comprehensive system to design, so as to be more ideal Electric vehicle controller. And should not be commercially available as long as there is stepless speed regulation, brake power, soft start ... ... and other functions of the electric car governor. For the actual use of electric bicycles, we brushless electric bicycle controller design has been improved, the addition of the following functions:

First, the electric car controller has the output short circuit protection function

The controller can be directly connected to the output short circuit protection, even in the motor at the highest speed action (often output the highest voltage at this time) direct short-circuit controller output, the controller can be very reliable protection. In the protection of the circuit automatically reduces the output current to protect the battery safety, this time the current is about 0.3A, and at any time to detect the output state, when the output troubleshooting, the controller can automatically return to normal control, with self-recovery function , So that the controller has a self-protection capability, improve the safety of the controller and the battery, but also improve the tolerance of the motor itself failure. For the actual use of electric bicycles, stall is one of the possible conditions, such as the controller can be a reliable protection on the output short circuit, then the motor stall conditions, the controller can also be protected, and protect the motor And the safety of the battery. If only the current limiting function of the controller, then the output of high current (such as current limiting 14A), which makes the battery (capacity of 12AH) in a high current discharge state (14A), will affect the battery life. In addition, the large current flowing through the motor winding, over time, will make the motor temperature rise, resulting in winding insulation aging, ranging from motor life, while burning the motor.

Second, the use of double closed-loop control system

The controller uses double closed-loop control system (brushless: speed / current double closed loop, brush: voltage / current double closed loop), due to the existence of current loop, you can achieve the current limit, that can protect the electric car in a variety of normal The maximum current output value will not exceed the set current limit value, to achieve automatic current limit, so that in any operating conditions, the battery will not appear more than the set value of the current discharge process to ensure the safety of the battery. In addition, due to the dual closed-loop with the role, can make the motor to achieve the best start-up process and acceleration process, so that the battery current is effectively used, which can increase the mileage of electric bicycles. The commercial controller because it is a single closed-loop control system, and rely on MC33035 (MC33033) chip current limiting effect, so the start and acceleration often occurs when the controller current output to the current limit protection running state.

Third, undervoltage comparison designed to match the voltage hysteresis loop

Some controllers on the market only have undervoltage protection, that is, when the battery voltage is lower than a certain voltage (such as 32V) block the controller does not work, it is easy for users to use the battery to start the voltage rise (that is, after the battery stops discharging , The battery voltage will rise 2 ~ 3v), resulting in battery over discharge. The controller undervoltage comparison designed for voltage hysteresis loop self-locking comparison, which can effectively avoid the use of battery recovery voltage.

According to the above design to improve the brush, brushless electric vehicle controller, by a variety of load conditions, a variety of road conditions driving test, proved that it has a high reliability. In the stall run and the output directly short circuit conditions can achieve reliable protection and improve the brushless electric bicycle controller in the actual operation of the degree of reliability, the improved controller can be achieved to reduce the controller failure rate, The purpose of vehicle repair rate. In addition, due to the role of the current loop, and relative to the general use of the controller can extend the distance of nearly 10%, driving the process of frequent acceleration and deceleration, repeated uphill, the role of current loop effect is more obvious.