The hall sensor is a transducer that varies its output voltage in response to a magnetic field. Hall sensors are used for proximity switching, positioning, speed detection, and current sensing applications. Three phase BLDC motor has three hall sensors inside that are used for electric bike widely.
36V 250W brushless geared motor is popular in Europe, but in North America, people like 36V 750W hub motor more. More and more people order and enjoy these two types of DC hub motors that are called classic electric bike motors. Now they have received by most of customers because of good quality.
But when ride this hub motor bike and climb hill for a long time. Sometimes over current or over head will break motor controller's MOSFET or hall sensor.
Hall sensor is broken. The hub motor can't work. Unless your controller can drive sensor-less motor. Buy a new motor, cost more.
Replace hall sensor, cost less. Below we first instruct one type of 750w electric bike motor .
If hall sensor is broken, power on battery, you will find battery gauge works, horn works, lights work, everything is good, except when you turn your throttle, the hub motor wheel can't run.
Step 1:
Retest this hub motor and make sure it does be broken. Do you have voltmeter?
Still connect all wires and power on.
First measure 6-pin hall sensor plug, the voltage as below:
1.The voltage of red and black is about 4.5V;
2.The voltage of yellow and black is about 4.5V or 0V;(use hand to turn hub motor, the voltage will change from 0V-4.5V)
3.The voltage of green and black is about 4.5V or 0V;(use hand to turn hub motor, the voltage will change from 0V-4.5V)
4.The voltage of blue and black is about 0V or 4.5(use hand to turn hub motor, the voltage will change from 4.5V-0V)
If you can get above data it's no problem with bike conversion kit system. If the voltage of Item 2 (yellow and black wires)can't change from 0V-4.5V,Please replace this hall has a yellow wire connect.
You should prepare some tools and material:
1.Hexagon wrench (Necessary)
2.Hammer (Necessary)
3.Screwdriver
4.electric iron
5.A-B glue
6.insulated paper, insulated wire
7.scissors
8.New hall sensor
Step 2:
Take off nuts and gasket on axis and use hexagon wrench to loose 16 screws.
Step 3:
Make the electric bike motor stand and cable is bent inside. Left hand hold the hub motor and use hammer to knock the axis.
Step 4:
After some knock, the cover will take off hub.
Step 5:
Use the same way to knock the other axis, the other cover will also take off hub.
Step 6:
When both side covers are off hub, next we should take out the rotor-winding. Make the axis stands on the ground, both hands press hub motor, the rotor-winding will out of hub.
Step 7:
There are three hall sensor in three grooves around the rotor.
Use scissors to remove insulated wire and insulated paper. You will find 9-pin(three hall sensor)connect to PCB on rotor-winding. Each hall has three pin: 1:+ , 2:- ; 3:signal
For example:
Hall A: 1:+ , 2:- ; 3:Yellow wire
Hall B: 1:+ , 2:- ; 3:Blue wire
Hall C: 1:+ , 2:- ; 3:Green wire
Step 8:
Just now had known yellow wire hall sensor was broken. Please use electric iron to remove Hall A and use A-B glue to fix new hall sensor. Use insulated paper, insulated wire to fix PCB. Then re-build this hub motor.
Step 9:
Test as step 1.If can get the data from each hall sensor. Congratulate.
Power on battery, the hub motor wheel works.
Hub motor, BLDC motor, electric bike motor  supplier: Leaf Motor Technology Co., Ltd
Website: https://www.leafmotor.com/

Problem with electric bike hub motor kit

Good day.I have bought from you 1 set of 48V 1000W rear electric bike kit that includes 48V 12Ah li battery,48v lcd brushless motor controller,twist throttle,brake levers with 26” 1000w hub motor rear wheel.Received all things.The order number lf283218U578679K. Shipment was fast and packing box was not broken.
But since I had installed hub motor wheel,motor controller,throttle..everything, I had following problems: Twist throttle was sometimes hard to begin electric bike motor uphill, with even slightest elevation.Electric bike kit either stops unintentionally, while I begin to accelerate hub motor, or doesn’t start at all. Usually it takes several amperes to start throttling.Electric bike motor never gets hot, only a little bit warm.
Electric bike kit (regenerative) brakes almost didn’t work at all. It is possible to stop with them only from the lowest speed of 5km/h approximately. If the speed is more than this, brakes just let the hub motor to freewheel. I don’t know if they are converting electrical energy.
When I tried to use USB cable to see, if it is because of lcd hub motor controller settings, I couldn’t connect to it. Software starts, when I choose “Connect” nothing happens with the program itself, only the electric bike motor starts to beep constantly. “Get settings” didn’t load any, changing parameters and saving them seems to have no effect on the electric bike motor behaviour. Only “Disconnect” button worked, but somehow it says that “Get settings” is complete, and any changes in parameters reset to their initial state. After approximately 360km, “Cruise control” button stopped to work. I opened hub motor and checked electrical connection to the motor controller itself, the button itself and wires are functioning properly. But I have absolutely no voltage reading on the button’s wires.
Read article from blog and forum,I doubt the problem comes from electric bike battery.It as said,there is a BMS inside li battery.Some cells would be dead because of overcharge or overdischarge.If dead,can’t charge li battery.Even if charge it,green led on charger will light at once.It looks like full charge,actually no any electrical energy inside battery.So when I ride my hub motor electric bike,the electric bike motor will stop in short time.
Please, help me to resolve those electric bike kit problems, especially, with “Cruise control” button.
Hub motor,electric bike motor,electric bike kit supplier: Leaf Motor Technology Co.,Ltd
Website:https://www.leafmotor.com

The basic principles of the permanent magnet BLDC motor

We talk about one type of permanent magnet bldc motor for electric bike. It’s a bldc electric bike motor , sometimes we also call it brushless dc hub motor .
The permanent magnet bldc motor and the bldc motor driver is a typical product for e-bike recently.
Generally the electric bike motor ’s stator windings is made of a three phase star connection, with the three-phase asynchronous AC bldc motor is very similar. The hub motor rotor has been magnetized permanent magnet, in order to detect the polarity of the hub motor, there are three halls sensors on the rotor.
The bldc motor driver is made by the power electronic devices and integrated circuits, its function is to receive electric bike motor ’s start, stop and brake signal so that control the hub motor to start, stop and brake; receive the position sensor signals and reversing signal, used to control the inverse power tube change the bridge off to produce a continuous torque; receive the speed command and speed feedback signal used to control and adjust the speed; provide protection and display
The main circuit is a typical voltage-type AC – DC – AC circuit, inverter and other pieces of alternating square wave frequency of 5-26KHZ modulation wave symmetry.
Permanent magnet NS alternating exchange, the position sensor phase difference of 120 ° U, V, W, square wave, combined with the six-state encoding signal forward / reverse signal generator: 101,100,110,010,011,001, through processing logic components to produce conduction of T1-T4, T1-T6 turns on, the T3-T6 conduction, T3-T2 turn-on, turn-T5-T2, T5,-T4 conduction, which means that the DC bus voltage is incremented A + B-, A + C-, B + C-, B + A-, C + A-, C + B-, so that the rotor turned a pair of NS pole, T1-T6 power tube fixed into six states followed by conduction. Each state, only two phase windings are energized in order to change a state, the axis of the magnetic field generated by the stator windings 60 ° electrical angle of rotation in space, the rotor follows the stator magnetic field rotation is equivalent to the space of 60 ° electrical angle position, the rotor in a new location so the position sensor U, V, W to produce a new set of coding according to the agreement, the new coding and changed the power tube combination of conduction, the magnetic field generated by the stator winding shaft forward 60 ° electrical angle, and so on, permanent magnet electric bike motor produces continuous torque, drag the load for a continuous rotation. Permanent magnet DC motor commutation is itself, rather than forced by the inverter commutation, also known as controlled synchronous hub motor.
Hub motor, bldc motor, electric bike motor supplier: Leaf Motor Technology Co.,Ltd
Website:https://www.leafmotor.com