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Which electric bike controller should you use

Which electric bike controller should you use?

electric bike controller
When trying to decide which controller to use in your new electric bike, there are several options to consider. First, make sure that the voltage and current requirements and the electric bike controller can handle them. Running too many amps through the controller can cause it to overheat.

Types of speed controllers for different motors

It is very important to choose a motor controller that matches the rated power of the motor you are using and the voltage of the battery pack. A 24 volt controller and 6 batteries will drive a 36 volt motor, but the speed of the motor will be limited and will not reach its claimed output power (in watts). However, controllers that run at a lower rated voltage than the battery and motor run the risk of overheating and burnout of the connector.

Choose a speed controller for your motor

It is also important to match the controller and motor type. Brushless motors require brushless motor controllers. Some controllers require motors with Hall sensors, while others can operate without sensors. Switched reluctance motors have the best effect when used in conjunction with complex sine wave controllers. This type of brushless controller requires additional cost, but provides smoother acceleration.

Brushed motor controller

A 500W electric bicycle brush motor controller is simpler than a typical brushless speed controller. The speed of a brushed DC motor depends on the input voltage and can be controlled by a rheostat, so an electronic “controller” is not absolutely necessary. The efficiency of brushed motors is also often low, so the brushed motors eBike cannot get the same range as the usual 36 to 48 volt battery packs. This is why most electric bicycle manufacturers have switched to brushless motors.

Brushless motor controller

Most electric bicycles use brushless DC motors. These require the use of brushless motor controllers. They can rely on internal sensors in the motor to understand the speed of the motor or operate based on feedback in the power cord.

Sensors and sensorless controllers

If the motor of your electric bike conversion kit includes a Hall sensor, you can choose to use a sensored or sensorless speed controller. If you have a sensorless motor, you need to use a brushless motor controller that supports sensorless operation. If so, please check the product description of your motor first. If not, or if you can’t find the answer in the product information, look for the number of wires on the motor. A motor with a sensor usually has 3 to 5 additional wires and its wire throttle connector.

Direct drive motor and gear motor

Compared to gear motors that provide similar peak output watts, direct drive motors may require higher current controllers. This is because direct drive motors use high starting torque, which means a higher ampere peak controller is required to prevent damage to the controller. However, the geared motor will run at a higher voltage.
electric bike controller 

Voltage and current

In addition to matching the motor speed controller with the type of motor used in your e-bike conversion kit, you must also ensure that the e-bike brushless motor controller can meet the continuous power and ampere requirements of the motor and battery system. A 36 volt, 500 watt peak motor would require a controller with a capacity of 14 amps.

Additional motor speed controller options

Modern electric bicycle motor speed controller design can realize precise speed control and low noise. The sine wave electric scooter controller provides a smooth start and reduces torque pulsation.

Variable assist

The common 36V 500W electric bicycle motor controller has connectors for the throttle and speed sensor wires, which can provide smooth acceleration and provide multiple pedal assist modes. If you want to display options such as speed, voltage, and assist level displays, make sure that the motor speed controller has appropriate wiring and connectors.

Speed control

Some electric bicycles allow you to set a speed limit when using throttle assist. This is usually achieved by programming the motor speed controller. There are sophisticated controllers that provide CAN bus data, so you can use the display to show power level, battery voltage, speed, and estimated remaining mileage.

Regeneration of throttle and brake energy

If your motor and drive allow it, some electric scooter speed controllers and eBike controller systems can allow the motor to work as a generator when you slow down or go downhill. This can expand the range of certain areas by as much as 10%.

The MOSFET used for the speed controller of the electric bicycle motor is the most produced semiconductor device in the world. By 2009, there were more than 200,000 electric bicycles in operation in the United States.

Choose a controller for your electric bike

How to make the best use of rated power?
The rated power in watts may be a useful (if not accurate) motor performance guide. Be sure to check the product specifications carefully, because some motors list the input power, while others list the rated voltage and current. The continuous output in watts is usually 70-80% of the input watts. The continuous rated power of 500 watts is an intermediate motor suitable for electric bicycles.

How fast is the 500W EBike?

Depending on the rider’s weight and bicycle design, a 500-watt electric bicycle can usually cruise at speeds of up to about 20 mph. However, using a combination of motor and pedals, some riders may run faster.
electric bike controller

Can a 36V controller handle 48V voltage?

Most 36V controllers may have protection circuits and can limit the voltage, which means that most of the time this will not be a problem; however, you should never use a controller with a rated voltage lower than the battery pack voltage and motor operating voltage, because this There will be the possibility of overcurrent and overheating, resulting in damage to the controller. In addition, your motor may not reach its rated output.

The electric bicycle controller connects all electrical components together. Once you pull the accelerator or start pedaling on the pedal assist model, you will connect an electrical switch to create a complete circuit in which current can flow, tell the controller and then connect the circuit from the battery to the motor, and LCD if your Electric bicycles have screens.

Important warning for DIYers

Regarding the electric bike controller, the most important thing you must understand is that the rated voltage of the controller must match your battery. The more current the controller outputs, the smaller the volume and the more expensive it is. This is very important for DIY electric bike manufacturers or those planning to upgrade their electric bikes later. The quality of the controllers vary greatly, but unfortunately, there are not many brands with distinguishable brand names, so it is difficult to determine which electric bicycle controller is good.

You can rest assured that most electric bike controllers made for 24v-48v electric bikes below 500 watts are made with the best quality and can keep these electric bikes running for many years. You need to be careful when buying or assembling a custom electric bike that exceeds these specifications, because a higher quality controller is required to handle the extra voltage and wattage that will pass through the controller.

The two components of the electric bike controller connect the battery and the motor to:
Electric bicycles have two main electrical components connected between the battery and the motor. I will now study these in more depth.

Computer: LCD display and battery indicator

Many electric bicycles are equipped with a full LCD display, which allows you to measure the performance of the electric bicycle. These are usually found on electric bicycles of $1,000 and above. On bicycles under $1,000, an LCD screen is usually not included, but there is a battery indicator on the battery itself or on the handlebars, which you can use to measure battery life and remaining distance or time.

Switch: throttle and PAS

Every electric bicycle is equipped with a switch to turn the motor on and off. There are two types of switches, throttle (twist or thumb button) and PAS (pedal assist system). The switch type on each electric bicycle is listed in the specification section of the product description. We recommend that you buy electric bikes with throttle and PAS options so that you can use them when they are most useful to you.

In conclusion

The controller is essential for your electric bike. Without this small device, your bike will not work. Therefore, it should have more energy than the motor to increase the reliability of the system.
From the above article, we have presented all the information about electric bike controllers. At the same time, we also understand the reasons behind this. Hope to start now; after doing some research, you will buy the controller from the market or online.

If you are looking for a new way of commuting or want a healthier lifestyle, we are here to help you. Visit our website to learn more about electric bikes and electric scooter or please leave information to us.