When selecting the ideal E-bike controller, take into account the following factors:
Power and Controller Voltage
When choosing a motor controller, check the voltage and power. If you buy a non-programmable controller, ensure its voltage and power are equal to or slightly higher than the motors. If the engine is 24 volts, so should the controller.
Programmable controllers can limit this power. The voltage of the controller, battery and motor must equal. This will reduce the controller’s heating and increase its reliability.
Rating for Controller Current
Ensure the chosen controller has a lower current rating than the battery’s output current. A 9-MOSFET controller’s maximum current is typically 25A, compared to 18A for 6-MOSFET controllers, 40A for 15-MOSFET controllers, etc.
Batteries’ phase and current
The battery current and phase current are sometimes confused by novices. These are two distinct objects. The motor is connected to the phase current. The phase current may exceed the battery current by a significant amount.
Take a welding machine, for example; it draws 10A from the network and outputs 100A total. The controller operates on the same idea. It has a 30A battery draw capacity and can supply 80A or so to the motor.
You must ensure that the phase current of the controller and the current motor match when picking an E-bike controller for the motor. The controller will become increasingly hot if it supplies more recently than the existing motor capacity can handle.
The varnish coating on the wires loses its quality when the motor overheats. It causes a short circuit, which causes the engine to warm up rapidly and harm the windings.
As a result, the phase current of the controller in standard E-bike controllers must coincide with the motor current. If so, this setup will prevent individual components from failing.
Sine wave vs. square wave controllers: what is the controller driving type?
The phase voltage waveform of the two controllers is different. One produces a rectangular waveform, whereas the other has a sinusoidal waveform.
Due to their lower noise generation, sine wave controllers are widely used. As a result, it is more effective when climbing hills or lifting big loads. Additionally, these controllers control general operations more smoothly and predictably. Sine wave controllers, however, use a lot more energy and are, therefore, more expensive. Additionally, they can only run on matched motors.
Due to their lower price, people like square wave controllers. They can run on a variety of motors. These controllers offer increased efficiency when abrupt braking or acceleration occurs.
They provide more noise and less smooth or punchy control than sine wave controllers. Additionally, square wave controllers have worse motor efficiency when climbing a hill or pulling a large load.
Is it a Dual-mode controller or a Hall Sensor/Non-Hall Sensor drive?
The controller must be Hall-sensor or dual mode if your E-bike motor has a Hall sensor. The motor’s hall sensor detects rotation, and the controller generates a voltage in response to sensor signals.