How to make a Speed Controller for Electric Bike
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- čas přidán 6. 09. 2024
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In this video I am going to show you how to make a powerful PWM speed controller for electric bike.
We have been working on converting our bicycle to an electric bicycle and as we are donw with the mechanical part of the project we needed a speed controller thats capable of handling 84v battery pack.
Most of the options avliable online are not rated for that much high voltage so we eventually decided to built one for ourself.
This homemade PWM speed controller is made for our electric bike. Its capable of handling upto 95VDC and 2000 watts of continious power output.
Schematic,Gerber files and Components list:
www.pcbway.com...
Regards.
DIY King
Corrections:
The voltage is regulated using buck converter IC LM5008.
The 555 timer IC cannot be operated above 15v.
can u please tell if the voltage from buck converter is used for 555 timer or the dc motor.
how about a brushless less sinosidal esc ?
@@bumblebimmer e-bay man, $25-$45 for most up to 1kw, it may not be pure sine wave, but it works! I I have a 48v -72v 1500w, I'm going to modify, to get 2kw+ and maybe 96v, I have toyed with the idea of using a small ESC, 350w or so, use its ' logic controls' to power the gates of my own MOSFETs, maybe not do effiencent, may not have safety features, and have to rely on fuses or breakers, but should do about 96-120vdc, and 4kw, and be clunky and junky looking, but it could work, it could possibly run a modified 3phase ac motor? I'll have to look in to that one,
Can we use 7812 transistor for 555ic to provide 12v
Hi DIY King! thank you for a great project. Please tell me what is the minimum battery voltage required for this circuit to work, is 40 Volt enough to start?
I'm surprised by the lack of comments demanding Flux. Get yourself some flux. It will make soldering those tiny components some much easier. Nice job either way!
Switching MOSFET by NE555 out pin and 1k resitor is not proffesional (slow GATE trigger and MOSFETs are heating up) , you can use driver MOSFET will be pro. (Schematic is one big chaos). Sorry for my criticism ; )
this man knows what he is doing
Great work. Unfortunately , there is no much practical use for DC brushed controllers nowadays since brushed motors aren't used for this purpose anymore. BLDC's with three phase controller are used because of better efficiency, lower noise , advanced torque control mechanism etc. And most important - no need for brushes replacement thus higher reliability. Of course , if you have time and brushed motors laying around, knowledge in mechanics and patience , this is cheap and interesting solution. Veri nicely done. Thank you.
Do you do contract work? I need a custom speed control
dunno much about the various electronics parts but the soldering technique was spot on. 👍🏽
BUT... that works only for a brushed motor, not for any of the brushless motors so common on ebikes today, especially hubmotors.
Awesome speed controller! 👍😊😊 Nice idea
heyy! will u try to sell the pcb board if you are having few extra's.
Im curious as to when the bike is actually ridden. A wheel under no load doesnt tell us how robust the speed controller is .Also is there a twist throttle available as a resistor ? AND ...from a standing start theres a huge current spike that tapers off as you get moving and the load tapers off as you get up to speed . I dont think those fets will handle very much current
Hi do you have same files for bldc motor also
which motor use in making electric bike
thank you..you are truly the king in DIY
Hi
I have a 58.8v hot chili dh converted bike... I had to remove the shield to make everyone fit and using it like this for 3month...still when a cloud is coming I m not very proof of me... Do you think if I coat it will be enough?
Programing needed or not
On the road testing is important as well as with load n on a slope continue testing for hours. This only an initial testing without a weight.
How to make car recever and remote
Hi bro I need some help. In my college they have given me one project. Basically what I have to do is i have to make integrated Electromotive wheel that should be fit in one cycle and whatever components i have to use that should be there in that wheel only, it should be come outside. And at handdle accelerometer should be there and the connection of the accelerator to motor should be the wireless communication, so for that what I can do .... Please bro help me.
Is the motor a DC Brush type or a brushless? Doest your creation work for both types?
Ok but how can we with throttle⁉️
Very good project 👍
how much did 1 pcb board cost you?
Do you or any other produce these? I need to use for e bike with 24v battery and 500w motor and throttle
Pretty nice job, bro. 😊
Great Gob, well done and Thnx, which software use for schematic design
hi can i use this same speed controler for the alternator motor?
24vol 20ah hub motor controller Bana ke dikhao pzz
How is that vertical brushed motor driving the wheel? I can see it's a worm drive but what is the confifuration of 2nd gear on wheel?
Hello could you please tell us the list of the electronics pieces. ?
Thank u .
#It is great👌👌
What's your thoughts about building a alternator regulator, that can do the CC CV then shut off, for lithium batteries? It would need a 12/24v nominal, approx, that is PWM, according to the charge needed, and a volt sense, and current sense, and temp, sense, and regulate output accordingly, limmit current from 25a to 150amps +, you seem to be the guy, it is far beyond my capabilities, I have a 7s lithium ion bank, I wnt to charge it to 28-28.7v it can go to 29.4v and can handle over 150 amps charge, I have 130 & 150 amp alternators. A similar regulator is nearly $500, because only one company has a monopoly, no one else makes a programmable milti-stage regulator, its basically a buck converter, using the alternator field as the inductor, I don't know how much logic it will require, if it would need a full on microcontroller, or if zenerand MOSFETs could accommodate some of the functions, I'm guessing microcontroller, probably something faster than the average Arduino! It would be a awesome pcb way video, and the voltage sense would need to be protected from possible high voltage, the alternator is capable of around 200-600+ volts, if it over shoots, outputing full field with no battery, a 12v alternator can charge up to 48-60v batteries, depending on a few factors, let me know if you are interested, I'm no big company, or a company at all, I'm just a guy with a need, and think maybe there is others who could use this also, there is alot of ppl with rv's converting to lithium house batteries, and charging with the alternator, can be the end of a big headache, and destroyed alternators, and very expensive batteries, but really, I just want a couple for my self, to charge the batteries for my offgrid home, I have2 banks, a 12v that I want to go to about 13.8 , and 28.7v for the 24v bank! I hope you are willing to help me, maybe we can make some money, with my skills , I could possibly assemble the circuits, on a PCB, but I can not program anything, I'm just a poor guy trying to keep the lights on! When there is no sun!! Thanks and have a great day either way! If I do not hear from you, I will ask later, I just subbed to your channel!!! Thanks again!!
Why would you need pwm?
I suspect you are overthinking this.
Something to supply dc - two 12vdc server power supplies in series, with a switch to supply either the 12v or 24v to a set of boost converters wired in parallel to get to the 150a you're looking for.
Used server power supplies would run about $100 delivered - the dc-dc boost converters are $17 ea on Ali with free shipping for 40a capacity.
There is a 2900w ps that is currently and frequently available for 50 bucks and will put out 12v 236 amps.
Just add enough boost converters to hit your desired output.
Add a BMS with enough series lines at the lowest amperage available, and use that to control a relay to cut power to the power supplies if vout from the converters hits the max threshhold because the bms only controls the input coil of the relay, you don't need one that is big enough to control your converter output directly.
HI Will you help me t develop a controller with few modification and its very interesting,
hello amazing video it would be possible to get the schemes to be able to experiment with variants of the circuit can learn in the process?
It works
Sir please make a 90mm brushed motor edf
can we use receiver and transmitter instead of that preset(vr)?
Hi there! thanks for sharing! So, How did you deal with the induction loads on the DC motor and the effects on the controller? Did you make any measure on what level the voltage reaches when the mosfets are turned off?
you are rock
Can I use this same design for a 24v speed controller
DIY KING HI CAN I GET UR NUMBER PLS
Which motor do you used in this bike please tell me
Its a DC motor so more details will be provided in the built video tomorrow so stay tunesd for that.
@@DIYKingSaM ok
Can you make a jigsaw powered by a RS775 Dc motor?
I wish you would build me a controler!!!
Well 👍 bro 😎 do more videos🎥
All the best👍💯
Thanks dear will bring more content
Ok bro😎
Thanks yaar you solve my problem
Can u make a pressure washer and gun
Which Fet's are u using
Bro isme throttle kese lagega??
We won't video of making the battery pack.will you post on it?
Pls reply
That part will be included in the upcoming video.
This is great!
I have a challenge and I’d like to know what you think…
I have a working e-bike with a very basic controller, everything works, however I am stuck with the out-of-the factory speed.
This bike doesnt even allow me to reach 25Km/h considering my weight.
All I wanted to do was to have a lil more speed, nothing crazy.
So I bought a KT controller and display thinking that I could change the speed limit.
The new controller is supposed to be better than the original, better mosfets etc..
However it doesn’t work. The display turns on the bike, I can even browse thru the parameters but it shows 0 battery charge, hence nothing works.
I tried all sort of things, like swapping the hall sensor cables to see if there was some mismatch but still nothing. Clearly there is current from the controller cause I measured 3.68V at the Throttle cable when the controller was plugged to the motor and battery.
Battery is 48V 15AH I dont think is the problem, the display turns on, it just doesnt comunicate with the motor (250W)
My naive question:
How can I proceed with modifying the new controller and make it “like” the original?
I thought about making a new one from scratch but it might be too difficult for me,
Besides I’d still have the display problem, I need one to turn on the bike, speed regulation, headlights etc..
I suspect it might be something “simple”, related only to the power circuit, perhaps once I get proper reading of the battery charge everything will work…. hopefully.
Any thoughts is greatly appreciated.
hi bro , i am making this as my final year project and with some extra modifications from a simple e cycle , i saw this video and i made list of the components and bought all the components but i didn't found LM5008 in any of the shops , so can you please give me the cheap priced link of the same. If not then please give me any alternative buck converter circuit for this controller , i need to finish this project asap within a week to 2 weeks. I live in bangalore , so if you know any shop over there then please let me know asap or provide me any alternatrive circuit for 24v 250w dc motor , or please send me the buying link.
Where you study to make circuit board
Thanks for the good work!
Where to purchase it. I want 60v 20 amp controller. Plz give number
As you know there is summer now my request is that build refrigerator....
Nice bro 😎 😎
Very good project
Gr8 bro.. Do upload complete series soon
Next video is coming shortly
Can you share your Gerber files i want to make it
PCB pdf layout dalo
Looks very good.
Indeed
fantastic.....
Which type of motor you used and where to find it
Its an automatic door motor and I found it from scrap.
@@DIYKingSaM can you tell me motor which available on e-commerce site thats torque and speed same as you used
Plz make a all parts working robot
First like 😁😁
bro please upload your videos on time
I think you use car wipper motor
Next project: make a jet engine
Awesome
Flawless work could you make me a speed controller for my ebike same one plz I'll pay you could make you a buisness from it.
Sir where is ebike
wow
Sir please talk to me
Please sir can you make electric bike
And defenitely over volted like crazy!
Too complicated for me.
Nyc
Have you done electrical engeneering
Nope
Make electric cycle from bike self motor
They are not made for continious operation
Are bhsi isko chalakar nehi dikhsya
Dekhaya hai... watch the end part.
Nehi
road me chala kar nehi dikhaye ho
?
Brother can you send me 5pic I gave you money I am from India