A comprehensive guide to ebike controller and maintenance tips

How ebike controller works

The working principle of the ebike controller is to process sensor signals through the circuit board and control the motor’s speed and steering according to the vehicle’s driving status and user operations, thereby realizing the ebike’s driving, acceleration, deceleration and steering functions.

Specifically, when the user presses the accelerator pedal or turns the steering handle, the corresponding sensor sends out signals, which are received and processed by the circuit board. The circuit board controls the speed and steering of the motor through the drive circuit according to the preset algorithm and logic, thereby achieving ebike driving control.

Functions of ebike controller

Here are the main functions of an ebike controller:

• Speed adjustment: According to the output of the handlebar, the speed of the ebike can be adjusted steplessly.
• Brake power-off: When braking, the ebike controller automatically cuts off the power supply to the motor, realizing power-off first and then braking.
• Current limiting: When the current exceeds a certain value, it can automatically limit the current output to protect the motor.
• Battery under-voltage protection: The under-voltage protection value of a single battery is 10.5V. When the bike battery voltage drops to a value of under-voltage protection, the motor will be powered off and stop working, thereby protecting the battery. The under-voltage protection value of 36V scooter battery is 31.5V; the under-voltage protection value of 48V ebike battery is 42V; the under-voltage protection value of 60V ebike battery is 52.5V.
• Speed limiting: When the speed of the ebike exceeds the specified value, the speed limiting protection circuit of the ebike controller cuts off the battery power supply circuit and limits the speed.
• Speed display: The 48V ebike controller is equipped with an instrument line, which can display the driving speed of the ebike through the instrument.
• Reverse charging function: When the electric motor is running, the ebike controller replenishes electric energy to the battery.

Common faults of ebike controller

There are five common faults with ebike controllers:

• It can start normally but stops running immediately after running a few meters:

If it’s not because of insufficient battery or poor line contact, it may be that the ebike controller model is installed incorrectly. For example, a 72V controller is installed when 60V is required, which leads to voltage identification errors and the ebike controller will prematurely initiate under-voltage protection.

• The meter shows that there is power, but the ebike will automatically cut off the power while driving:

First check whether there is poor circuit contact, and then consider whether the overhead power of the ebike is too small or the ebike’s driving current is too large, causing the circuit breaker to activate circuit protection. If the problem still exists after troubleshooting, it is very likely that the internal components of the controller are loose or have poor contact.

• The riding noise is loud, the load speed becomes slower, and it will shake when zero startup:

In this case, it may be that the motor Hall is damaged or there is a problem with the internal phase circuit of the ebike controller. If the Hall and connecting line detection are normal, it means that the ebike controller did not have enough time to learn the motor parameters and failed to learn the motor parameters completely.

• The instrument shows that there is power, but when turn the speed control handle, the data on the instrument panel does not change and the motor does not move:

First check the brakes. After the braking problem is eliminated, manually start the motor. If the motor cannot move, it can be initially determined that the problem is the breakdown of the MOS tube inside the ebike controller; if the motor can move, consider circuit problems such as the handlebar cable and the electric door lock.

• Engine abnormally accelerates automatically:

There are many reasons that can cause this phenomenon. The first thing to confirm is whether it is caused by water entering the circuit or an open circuit between the speed control wire and the negative wire of the controller.

How to maintain ebike controllers

The ebike controller is almost like the brain of an ebike, distributing current during ebike operation so that all components of the ebike operate in an orderly manner. However, once the ebike controller is broken, the ebike will be almost paralyzed. Then is the ebike controller really that easy to break? What causes the ebike controller to be easily damaged? How can we effectively maintain the ebike controller?

• Heat dissipation: When the controller is working, it will generate heat due to the electrothermal effect. And battery thermal management affects the electronic devices. Since the ebike controller of each ebike is placed in a different position, users must first find the position of the controller of the ebike and pay attention to keeping it ventilated and dry so that it can dissipate heat well. Once the heat dissipation is in place, the ebike controller will be more durable.
• Pay attention to road conditions: Many people like to pursue speed when riding ebikes and do not want to slow down even if they encounter bumpy roads. However, if they encounter particularly bumpy roads, rushing may cause the controller to disconnect or the connector to fall off. Therefore, when the road is difficult for riding, slow down or push forward to ensure that the ebike controller is not damaged.
• Repair or replace the controller: When the ebike controller is damaged, if it can be repaired under safe conditions, then repair should be given priority. If it cannot be repaired, then the maintenance personnel should help replace the original controller. Rather than just using a universal controller, the same model model or a model with exactly same parameters should be used, otherwise the ebike will become less durable. The original controller is always the best match for the ebike.
• Original controller: If users are worried that the ebike controller is broken and couldn’t buy the original controller, it is recommended to find one of the same model online in advance and put it in the shopping cart when purchasing the ebike, and then buy it when it’s needed. And then, just ask a professional to replace it.
• Daily maintenance: The service life of the ebike controller is closely related to the daily use and maintenance. During daily use, users must pay attention not to let water enter the controller; when using it, do not slam the accelerator, and do not push hard when the slope is steep, but use boost. If these are done well, the service life of the ebike controller can be greatly extended.

Choosing tips for ebike controller

The ebike controller is one of the core components of an ebike. When purchasing, users need to pay attention to many factors such as brand, model, matching, functional performance, stability and reliability, and after-sales service, so as to ensure the normal operation and safety of the ebike and lithium battery safety.

When purchasing an ebike controller, here are some points for reference:

1. Brand and model: Choose a well-known brand of controller and understand its model and performance characteristics to ensure the quality meets actual needs.
2. Matching: When purchasing an ebike controller, consider the specifications and models of the ebike motor and battery to ensure a good match between the controller and the ebike. For example, for a 48V ebike, users shall not buy a 60V controller.
3. Function and performance: Consider whether the controller has the basic functions and performance required for ebike driving, such as speed control, battery management, etc.
4. Stability and reliability: The stability and reliability of the controller directly affect the operation effect and service life of the ebike, so users should carefully understand the relevant performance indicators of the controller when purchasing.
5. After-sales service: Choose a brand with complete after-sales service so that users can get timely solutions and maintenance when encountering problems.