E-bikes have become increasingly popular in most urban areas in recent years. They make commuting easy. E-bikes use relatively smart technology. They have controllers, batteries, electric drive systems and engines. All these components make e-bikes more complex and expensive than regular bikes.
The e-bike controller is the key component of any e-bike. Without a controller, the motor will not run; therefore, the bike will not start. If your e-bike controller suddenly fails, how will you recognise the problem? What methods or procedures are there to follow when testing your e-bike controller? Does the e-bike controller need to be replaced or repaired?
In this article, we'll take a look at e-bike controllers and how to test if it's working properly. Read on to find out more.
What is an e-bike controller?
The e-bike controller is the brain of the e-bike; it is a circuit unit responsible for controlling other bike components. It controls the speed of the motor as well as the start and stop functions. The e-bike controller connects to every electronic component of the bike, such as the throttle, battery, display, motor and speed sensor.
The controller is a unit consisting of the main chip (microcontroller) and peripheral components (sensors, resistors, MOSFETs).Inside the controller there are signal processing circuits, AD circuits, power device driver circuits, PWM generator circuits, overcurrent protection circuits, power circuits, undervoltage protection circuits, and so on.
Function of E-bike Controller
The main function of an e-bike controller is to accept input signals from the electrical components (speed sensor, throttle, motor, battery, display) and then decide what signals to return to each component. It also controls all the central safety and protection mechanisms of the e-bike. These protection functions include:
1. Overcurrent protection
If the current is too high, it reduces the amount of current flowing to the motor. The controller checks the amount of current flowing to the motor. If too much current is generated, it automatically shuts down the motor. This function protects the e-bike motor and FET.
2. Over-voltage protection
Shuts down the motor when the voltage is too high. Prevents overcharging. The controller monitors the battery signal regularly. When the voltage is too high, it sends a signal to the motor to shut down the e-bike.
3. Low voltage protection
Shuts down the motor if the battery voltage is too low. It prevents over-discharge. It works similar to the overvoltage protection described above, but occurs when the battery voltage is low.
4. Brake protection
Shuts down the motor when braking. It gives priority to the braking system for the safety of the rider. When the brake is applied, it signals the motor to switch off and stop riding. This is a higher priority signal than others.
5. Over Temperature Protection
If the temperature is too high, it shuts down the motor. The e-bike controller is responsible for tracking the temperature of the Field Effect Transistors (FETs). These transistors are electrically charged. When the temperature of the FETs gets too high, the controller sends a signal to switch off the motor to avoid short-circuiting the transistors.
How to Test Your E-Bike Controller at Home
Basic e-bike troubleshooting is a skill that every cyclist should have. For example, learning how to test an e-bike controller at home can prevent you from grounding your bike. There are two ways to test an e-bike controller:
1. using a multimeter
This method is more technical than using an e-bike tester; you will need a multimeter, controller, and batteries. Below is a step-by-step guide on how to test your e-bike controller using a multimeter:
Step 1: Connect the controller to the battery.
Step 2: Set the multimeter to read. This depends on what you are testing, resistance or continuity.
Step 3: To test continuity, set the multimeter to continuity. Connect the black multimeter cable to the negative terminal of the battery.
Step 4: Test each line coming out of the controller. If you hear a beep, there is a short in the line.
Step 5: Set the multimeter to resistance mode to test the resistance.
Step 6: Repeat the steps for checking continuity; except, in this case, you should read the number displayed on the multimeter.
If the reading is below eight thousand ohms, the wiring is damaged or not working properly.
2. Use an e-bike tester
Using an e-bike tester is more beneficial because you will be testing the controller as well as all the components of the bike. There are different types of e-bike testers available in the market. Below is a step-by-step guide on how to test the e-bike controller using an e-bike tester:
Step 1: Remove the e-bike controller from the bike.
Step 2: Disconnect the throttle from the bike and connect it to the e-bike controller. This is to confirm that the controller is getting a signal from the throttle.
Step 3: Connect the e-bike tester to the controller.
Step 4: Switch on the bike tester.
Step 5: Switch on the throttle and observe the signal on the controller.
If the tester light is blinking, it is working properly. If only the middle light flashes, you have a problem with your controller.
E-bike Controller FAQ
Why does my e-bike keep stalling?
There is no specific direct answer to this question, as an e-bike switching off can be caused by a variety of faults, such as a drained battery, loose connection, low battery, worn out motor, and so on. However, the main cause of this is insufficient motor power or voltage.
How do I choose a controller for my bike?
When purchasing a controller for your bike, make sure that the voltage controller is the same as the motor voltage and the power controller is the same as the motor power. However, if you buy a controller for a specific motor, please double check the power and voltage controllers.
What is the service life of an e-bike controller?
The service life of an e-bike controller is generally 3-4 years, similar to the service life of a motor and battery. You can use a multimeter to test the voltage through the terminals to determine if they need to be replaced.
How do I reset my e-bike controller?
The process of resetting your e-bike controller may vary slightly from manufacturer to manufacturer, but here are some general steps for you to follow:
Switch off the e-bike and disconnect the e-bike's battery
Wait a few seconds (at least 10 seconds) before inserting the battery back in.
Switch the e-bike on again and check that the e-bike controller has been reset
How do I know if my e-bike controller is broken?
There are several signs that your e-bike controller may be faulty, here are some things to look out for:
The motor is not running properly
The display or lights don't work
Problems charging the battery
The e-bike controller is too hot
Conclusion.
Usually, you can test your e-bike controller at home using a multimeter or an e-bike tester. When using a multimeter, you can perform two tests:
Resistance test: this measures the amount of resistance and if the multimeter reads less than 8 kilo-ohms, you can tell that there is damage.
Continuity Test: This will show you if you have a short circuit due to snooping.
If the middle light comes on, you will know if there is a problem with your e-bike controller. However, if it is working properly, all five lights will continue to flash. We hope you found this article useful. Now that you have these skills, you can test your e-bike controller at home with confidence.
