In recent years, e-bikes have become increasingly popular in most urban areas. They make commuting a relaxing experience. Electric bikes use relatively smart technology. They have controllers, batteries, electric drive systems and motors. All these components make e-bikes more complex and expensive than regular bicycles.
An e-bike controller is a key component of any e-bike. Without the controller, the motor will not run; therefore, the bike will not start. If your e-bike controller suddenly malfunctions, how would you identify the problem? What methods or procedures need to be followed when testing an e-bike controller? Does your e-bike controller need replacement or repair?
In this article, we'll take a look at an e-bike controller and how to test that it's working properly.
What is an E-bike Controller?
An electric bike motor controller is a specific component that connects electrical components to make the bike perform better. The device connects the display, throttle, motor, pedal assistant, battery, and other sensors, among other things. It effectively manages all functions of the bike. Generally, these controllers come in a protective sealed box for better protection.
How does an e-bike controller work?
Basically, the electric motor in an e-bike converts electrical energy into mechanical energy so that the bike gets the power it needs to perform. The controller draws energy from the battery. It transfers energy to the motor based on user input and sensors.
When you turn the throttle, you can adjust the power of the bike controller. Therefore, it helps you control the speed of your bike. An e-bike motor controller is responsible for tracking pedal activity, battery voltage, motor power, acceleration, speed, and other important functions on an e-bike.
Additionally, it controls the pedal assist you get while riding the bike. However, regional laws regulate the scope of whether you can use an e-bike equipped with a throttle.
Functions of Electric Bike Controller
The main function of an e-bike controller is to accept input signals from electronic components (speed sensor, throttle, motor, battery, display) and then decide what signal to return to each component. It also controls all central safety and protection mechanisms of the e-bike. These protective features include:
1. Overcurrent Protection
If the current is too high, it will reduce the current flow to the motor. The controller checks the amount of current supplied to the motor. It will automatically shut down the motor if excessive current is generated. This feature protects the e-bike motor and FETs.
2. Overvoltage Protection
Shut down the motor when the voltage is too high. It prevents overcharging. The controller periodically monitors signals from the battery. When the voltage is too high, it sends a signal to the motor to shut down the e-bike.
3. Low Voltage Protection
If the battery voltage is too low, shut down the motor. It prevents excessive discharge. It works similarly to the overvoltage protection above, but when the battery develops low voltage.
4. Brake Protection
Turn off the motor when braking. It prioritizes the braking system for rider safety. When the brake is applied, it signals the motor to shut down and stop the bike. This is a higher priority signal than other signals.
5. Over-temperature Protection
If the temperature is too high, shut down the motor. The e-bike controller is responsible for tracking field effect transistor (FET) temperature. These transistors carry electricity. When the FET temperature gets too hot, the controller sends a signal to shut down the motor to avoid shorting the transistor.
If the battery voltage is too low, shut down the motor. It prevents excessive discharge. It works similarly to the overvoltage protection above, but when the battery develops low voltage.
4. Brake Protection
Turn off the motor when braking. It prioritizes the braking system for rider safety. When the brake is applied, it signals the motor to shut down and stop the bike. This is a higher priority signal than other signals.
5. Over-temperature Protection
If the temperature is too high, shut down the motor. The e-bike controller is responsible for tracking field effect transistor (FET) temperature. These transistors carry electricity. When the FET temperature gets too hot, the controller sends a signal to shut down the motor to avoid shorting the transistor.
How to test an e-bike controller at home
Basic e-bike troubleshooting is a skill every cyclist should have. For example, learning how to test an e-bike controller at home can prevent your bike from being grounded. There are two ways to test an e-bike controller:
1. Use a multimeter
This method is more technical than using an e-bike tester; you will need a multimeter, controller, and batteries. Here is a step-by-step guide on how to use a multimeter to test an e-bike controller:
- Connect the controller to the battery.
- Set multimeter readings. It depends on what you want to test: resistance or continuity.
- To test for continuity, set your multimeter to continuity. Connect the black multimeter cable to the negative terminal of the battery.
- Test every line coming out of the controller. If you hear a beep, there is a short circuit in the wiring.
- Set your multimeter to resistance mode to test resistance.
- Repeat the process for continuity; only, in this case, you should read the number displayed on the multimeter.
If the reading is below 8,000 ohms, the line is damaged or is not working.
2. Use an e-bike tester
Using an electric bike tester is more advantageous because you will also be testing the controller and all parts of the bike. There are different varieties of electric bike testers on the market. Here is a step-by-step guide on how to test an e-bike controller using an e-bike tester:
- Remove the e-bike controller from the bike.
- Disconnect the throttle on the bike and connect it to the e-bike controller. This is to confirm that the controller receives the signal from the throttle.
- Connect the e-bike tester to the controller.
- Turn on the bike tester.
- Open the throttle and observe the signal on the controller.
If the tester light flashes, it means it is working. If only the middle light is flashing, there's something wrong with your controller.