Controller strategies - Constant speed or constant power?

jbond

Esteemed Pedelecer
Jul 29, 2010
411
2
Ware, Herts
www.voidstar.com
Quite a lot of e-bikes now use brushless hub motors with a 3 way speed/power switch. As I understand it these modes set a top limit on motor speed. Even on single speed controllers these also set a max speed, typically the legal limit. On top of this there is also a constant current limit and a peak current limit. So this has the effect of limiting the power when the bike can't reach it's max speed due to a hill and so it's trying to draw more current than is safe for the controller, battery or motor. When there's a throttle attached as well as pedelec, the throttle seems to make the maximum speed of the motor variable up to the max for that mode. It may also vary the current limit and hence the power available. When the motor hits it's top speed for the mode, it stops providing torque usually due to the freewheel within the hub.

Ignoring legal issues for the moment. I'm wondering if it would be possible to have an alternate strategy where the modes set a power limit rather than a speed limit within a wider speed range. This range should have an upper sanity check such as 30mph. Real world power available would mean that this speed would be very rarely reached. Having a power limit would mean that the rider could set an assist level (50w or 150w, say) and then ride at whatever speed their own leg power plus 50w could achieve. On a ride with gentle gradients, I feel like this would result in slower ascents but using less power which ought to help range. And faster descents which would help A2B times.

This was all prompted by riding an Alien and finding myself switching from medium to low on ascents to use less power and get more range. And from medium to high to get the wind in my hair on descents. On the steeper ascents, the motor is trying hard to maintain it's relatively high top speed when I would have been happy to keep adding leg power and accept a slower ascent. Maybe I'm just asking for an automatic version of what I'm doing manually.

- Does this description make sense?
- Would it be sensible and/or an advantage over current controller strategies? I'm unsure of what the overall effect would be in terms of range and hill climbing ability
- Are there any controllers that work like this or can be made to work like this with the typical SB style hub motor?

I think this also opens up a different mind set. Instead of a moped that needs a bit of help from our legs, this would be a bicycle that gets a little help from the motor. This might allow a smaller, lighter hub and a smaller, lighter battery for realistic use and range. Or a battery of current size that offered a much larger range. This turns into a question that probably appears stupid. Instead of striving for 350w or 500w or more, how small and light can we make a 100w e-bike? And would the end result be frustrating or satisfying?

Back to the legal issues. This obviously opens up the ability to add power to a long downhill plus hard work from the legs to seriously break the pedelec speed limit. For the purposes of this discussion I'm really not interested. Or at least not until the same approach is applied to a faired recumbent and we're hitting 50mph.
 

wurly

Esteemed Pedelecer
Aug 2, 2008
501
9
Yeovil, Somerset
What you are describing is exactly what i have on my ebike. It is home built addition to the controller. It takes a reading from the battery pack and i set the threshold for the circuit to overide the throttle. This is how i get less than 10Whr/mile and can climb any hill without thrashing the battery/controller and motor. I ride with the throttle flat out and let my gadget do the work. I'm redesgning it with 'cruise' facility because i get arm ache winding the throttle open constantly. When i get the new design finished i will consider making some more depending how many folks are interested.
Mel
 

jbond

Esteemed Pedelecer
Jul 29, 2010
411
2
Ware, Herts
www.voidstar.com
Interesting. Is the basic bike a factory model or a DIY kit? What's the controller-motor-battery combo?

If you can get a signal out that represents the current being taken, then I guess it wouldn't be too hard to reduce the throttle voltage when a preset limit is exceeded. The controller would then back off the max speed/power being put in until the current dropped below your limit. Apart from the current signal, that could all be done external to the controller.

I'm not completely clear on what the throttle does on the SB controllers. It definitely reduces the max speed, but I'm not sure if it also reduces the power delivered when you're below the max speed. If there was a throttle plus pedelec mode that would solve your cruise control need. Unfortunately the switch on mine is either/or and there's no "and" position.
 
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Mussels

Esteemed Pedelecer
Jun 17, 2008
3,207
8
Crowborough
Ignoring legal issues for the moment. I'm wondering if it would be possible to have an alternate strategy where the modes set a power limit rather than a speed limit within a wider speed range. This range should have an upper sanity check such as 30mph.
Why 30mph, is it because that's what you think the limit should be? If you want to ignore legal issues then don't suggest your own speed limit please.
I regularly do more than 30mph on my bike and it's quite safe as long as I don't try overtaking.
 

Bandit

Pedelecer
Mar 13, 2009
44
0
I guess if you're skilful you can (with either type of drive) arrive at a balance between the watts you can (or are willing) to contribute and the watts the motor can contribute to achieve any particular speed. What less skilful riders like me might find helpful is to be able to fix the speed - like a cruise control on a car - and the effort we're willing to put in to achieve it so that the motor and controller are seeking to "top up" our effort as described.

This could then be made to work in reverse, enabling the controller to recover energy on a descent that would otherwise exceed the set speed. The amount of energy recovered would (unfortunately) still be pretty small, but it irritates me that my wife achieves better range than I do on an otherwise identical bike by virtue of a 15kg difference in weight. :)
 

wurly

Esteemed Pedelecer
Aug 2, 2008
501
9
Yeovil, Somerset
Jbond, correct, the controller doesn't know how much power is being taken from the battery. There are conditions where a lot more power is being used you are probably unaware of...usually at low speed. Backing off the throttle will reduce power, but if yours is anything like mine, it's either off or on and not much inbetween...all a bit vague. My current limiter takes out the guess work and balances rider effort with motor effort. If you need a bit more assistance adjust the limiter a wee bit more via a potentiometer. You would be surpised how little power is needed in reality even for hill climbing (at a resonable speed). Regeneration is a whole new ball game. I have no need for that as i prefer motors with a good freewheel and very little drag.
My setup is a 26" wheel 260rpm tongxin and brushless controller, ping 36V5ah. Top speed is 22mph. Hillclimbing mph best described as slow and steady, but not found one i can't get up yet. My wife's bike has one with bafang setup and JohnP has one on his tongxin hub bike getting huge range.
My new design will work on 36-75V input voltage and should work on most controllers. It will have a powerlevel indicator, adjustment control and wires for cruise and brake switches. I can see no reason why it can't be retro fitted to most ebikes, it's works like the cycle analyst, but much cheaper.
The throttle reduces the amount of pulse width (on/off pulses) given to the windings, which effectivly reduce overall power and current comsumption. At full throttle the waveform to the windings is effectivly full of pulses (more on than off) but that dosn't mean you are getting full power.
There was a thread here about power/ratings and Back EMF which was a good read.
 
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jbond

Esteemed Pedelecer
Jul 29, 2010
411
2
Ware, Herts
www.voidstar.com
Why 30mph, is it because that's what you think the limit should be? If you want to ignore legal issues then don't suggest your own speed limit please.
I regularly do more than 30mph on my bike and it's quite safe as long as I don't try overtaking.
It was a figure picked out of the hat and just used as an example. The point being that perhaps there should be some sanity check top speed rather than a hard limit that you hit often.