2012年4月27日星期五

How to build spokes on hub motor for electric bike ?

DIY electric bike conversion kit and convert your bike is funny. Sometimes we prefer to purchase spoke hub motor , bike rim and spokes. And build spokes on electric bike motor by ourselves.
If we want to convert 26inch front wheel, we should purchase 1 set of front spokes hub motor, 26inch rim and 36pcs of spokes. We can purchase them from leaf bike motor shop online.
Received goods and check them:
1. How many spokes you received. Generally we need 36 pcs spokes to built on hub motor and 12 gauge spokes for electric bike. 13, 14 gauge spokes are too thin, just for common bike.
2. There are 36 eyelet on bike rim and hub motor.
3. Check nipple and the dia. of eyelet on rim, make sure the nipple can put into eyelet.
Calculate the length of spoke :
If you use 205 leaf front hub motor, the eyelet to eyelet of rim is 511mm that is 26inch rim, spokes should be 155mm length.
You need below tools to install spokes on hub motor.
1.iron shelf
2.slotted screwdriver
3.nipple wrench
4.magnet
5.rubber hammer
6.tape measure
7.calipers
Done check, everything is okay. But we found the dia. of nipple is 4.5mm and the rim is also 4.5mm. These eyelets are too small. See pictures.
Get an electric drill and 4.8mm aiguille. Drill 36 pcs of eyelets on bike rim first. Adjust the iron shelf so that the dia. is 100mm. Because standard front fork is 100mm. Then put the rim inside the iron shelf, hold on the hub motor. Make the first spoke wear into hub from left side, the next from right side. One by one from left side to right side. Done install all 36 pcs of spokes, please check them whether correct. See pictures.
If no problem, we should hold spokes on rim by nipples First hold one spoke on left side, then cross to fix another spoke on left side. Next step, cross two spokes on rights side and fix them. Left side, right side, a group of four spokes. See pictures.
Fix all spokes, we should use wrench to tight spokes a little, please don’t be too tight. Use hand to turn wheel, make sure there is no noise from friction of rim and nipple. Use rubber hammer to knock rim when the wheel is running so that the rim will be not jumping up and down. Still to tight spokes a little. See pictures.
Turn wheel, you will find the rim from left side to right side. In order to make the wheel running in the middle. We use calipers to measure and get the data. Then use a magnet to hold a pin. See pictures. If rim to the left, we tight right side spokes or loose left side spokes. See pictures.
It takes about 1 hour to build an wheel.

2012年4月14日星期六

The Displayer Operating Manual for LCD motor controller

When you received leaf motor 's bike motor kit with the LCD motor controller .Don’t know how to handle it.
For example: 36V LCD motor controller
1. Power switch
Supply battery, press power switch once, the LCD panel will display total mileage, speed , battery capacity and the time (time will be recounted once the power is on).
Voltage ≥ 36V four cells
36V > Voltage ≥ 34.5V two cells
33V > Voltage ≥ 31.5V one cell (flash every 0.5 second)
Voltage < 31.5V no cells (flash every 0.5 second)
2. → Next button
Users may adjust freely between different levels of assistant functions by this button.
3. Set button
3.1 Press set button once, “KM” light is on. At this status, the single mileage will be shown in this area. You may reset it by → button.;
3.2 Press “SET” one time under the status of single mileage, total mileage will be shown. Press it again , it will display single mileage;
3.3 Press “SET” for 5 seconds, the light is on. At this status, you may set with → the size of wheel diameter from 10inch to 30inch in speed display area.
3.4 Fault code
Eight status of fault instruction from 01~05, 07~09 will be displayed in speed area when the light is flashing.
01: Abnormal connection between displayer and controller;
02: Excessive current is detected in controller. If the status remains the same after restarting, it is certain that something is wrong with the controller internal power devices.
03: Motor three-phase power lines are fallen off, or motor is stocked for more than 2 seconds. If the status remains the same after restarting, it is caused by undesirable contact of three-phase lines.
04: Battery is at the status of voltage protection;
05: Hall cables are not connected, or incorrectly connected.
07: It is wrong with the brake lever cable when system is running.
08: The controller internal current will detect if the circuit element is damaged. The status will be displayed if it is abnormal.
09: The battery voltage is measured all the time under the working state. If it is > 47V,the system will enter into high-voltage protection mode, stop working.
Bike motor, motor controller supplier: Leaf Motor Technology Co., Ltd
Website:https://www.leafmotor.com/

2012年4月10日星期二

How-to-build-a-hub-electric-bike-motor

These days hub electric bike motor wheels are used for e-bikes widely. Nearly all of hub bike motor are brushless gearless. Because of low noise, high efficiency, long life are popular with riders.
Order 1 set 12" 14" 16" 18" 20" 24" 26" 700c 28" inch hub motor kit, convert your common bike to e-bike is so easy. Directly front or rear drive your bike.
The important part is an engine -hub motor. How to build this electric bike motor?

Step 1: winding
Calculate motor power, speed RPM and confirm what type of copper wire would you use. Next is fix a rotor on the steel shelf, wind copper wires by handwork or machine. It takes about 1 hour to done it by handwork. And should use rubberized fabric to wrap your fingers. Nipping copper wires will break your fingers.
Step 2:soak paint
After winding should soak paint in order to be insulated. Use brush to put the insulated paint on the winding and make sure be soaked everywhere. It takes about 24 hours.
Step 3:press axis into rotor
Put axis into rotor winding and use a key to fix axis. Use A-B glue to paste three hall sensors on hub motor rotor, put 9-pin (three pin/each hall) into PCB and use insulated wire to fix it. Put 8-pin cable inside the axis and heavy yellow, blue, green wires to connect the three copper wires(Phase A,B,C) separately. Thin red, black wires are be weld to PCB + and - .
Step 4:paste magnet
Paste magnet inside hub, one N pole, next S pole ..one by one. More magnet, higher torque, more power. The height of our magnet is 30mm,6mm higher than other hub motor. In market,24mm high magnet only build max 500w electric bike motor. So our bike motor works at 36V can reach 750w.
Put the rotor winding inside the magnet hub, be careful hand. It has powerful magnetism.
Step 6:install two covers
Before installing both covers, we should press bearing into cover. Use hexagon wrench to tight screw nuts. When you hear "poop" from electric bike motor. That means install correctly. Done it.
Power on battery and use bldc motor controller to drive this hub motor. If no any strange noise. It's okay.
Hub motor, electric bike motor, bike motor supplier: Leaf Motor Technology Co., Ltd
Website:https://www.leafmotor.com

2012年4月8日星期日

Check your hub motor wheel - electric bike kit

Order 1 set of electric bike kit from manufacturer-leaf motor and convert your bike to e-bike is a fun. But sometimes when we receive packages and don't know how to hanle it. Follow us:
Before install electric bike kit, we should test it first.
Step 1: Deliver your package
Spent some days on Internet, at last found leaf motor 's electric bike kit is the best. Ordered it and paid by paypal. Waiting for... About 3 days later, post officer knocked my door (EMS) and sign in it.
Check packing box first ,if it's okay. Pls disconnect electric bike kit box.

Step 2: Check all goods in package
Take out 26" hub motor rear wheel, bldc motor controller, lcd, throttle, brake lever, three button switches, speed signal wire and some connectors from packing box. Check each goods and make sure everything doesn't have fault.

Step 3: hold on 26" hub motor wheel
Put the hub motor wheel on your frame fork and tight both screw nuts.

Step 4: install magnet detector

Step 5: connect wires
1.Plug male 6-pin hall wires from hub motor cable to female connector from bldc motor controller;
2.Connect heavy yellow, green, blue from hub motor cable to heavy yellow, green, blue from bldc motor controller, color to color;
3.Two grey wires: connect these two wires/half speed; disconnect them/full speed;
4.Throttle connector is 3-pin that is easy to identify. Red: +4.5V, black: GND, green: Signal 
5.Brake lever connector is white 2-pin.When hub motor is working, press brake lever is to cut off power;
6.Signal wire is black three pin plug that should be connected to white three pin female connector.
7.The other three pin connector from bldc motor controller is used for PAS;
8.Connect four pin lcd plug.

Make sure each wire is connected correctly. Power on battery.(Heavy red wire: +, black wire: - )Be careful,36V controller must work at 36V battery, if supply 48V DC, it will break the bldc motor controller at once.
Power on battery and press ON/OFF button on LCD one time, the LCD will light. Twist your throttle,hub motor starts to run. No strange noise...Press brake lever, electric bike kit system stops, loose it,the hub motor runs.
Pls watch video .
https://www.youtube.com/watch?v=SrwYae6zOMA
By test electric bike kit system, we found hub motor wheel, bldc motor controller, throttle.. everything is good. Next step is that  we start to convert them on bike.
Hub motor, electric bike kit supplier: Leaf Motor Technology Co., Ltd
Website:https://www.leafmotor.com

2012年4月6日星期五

Hub motor was very sluggish

Question:While trying to get the hub motor up and running here we have run in to some problems. After installing the hub motor wheel in the fork it was very sluggish to turn and took quite a bit of effort, not freewheeling at all. The first time we plugged the battery (fully charged 48V 12AH LiFePo4 at 52.9V) in to hub motor (without the throttle connected to the controller cable) the hub motor beeped three times. When we hooked up the controller cable black and yellow pin connectors to the corresponding ones on the throttle there was no response from the electric bike motor , but the battery level lights did light up. We tried both throttles sent with the same results.
As it was the weekend I went to the forum and looked there for assistance. I received some good feedback that the 3 beeps we heard were a signal that the throttle was not functionable which is what we found as soon as we hooked up the throttle. We have checked all the leads for correct amperage as per his instructions with positive results.
I am assuming that electric bike kit is bench tested before it leave there? The packaging was undamaged upon delivery and all seemed in good order upon receipt. If you could please advise us on what to do to get this resolved we would appreciate it as we want to get on with our trials here to be able to get out product to market by summer.
I have checked my throttle and hub motor controller wires against your PDF diagram and there seems to be some discrepancy? I wish my camera was working but I will describe my findings. Diagram Throttle Black 3 pin shows: Red? perhaps Orange?/White/Blue Our Throttle Black 3 pin has:
Orange/White/Black from core with black jump to yellow 2 pin Diagram Controller Black 3 pin has: Red? perhaps Orange?/black/Yellow Hub Motor Controller Black 3 pin has: Rust from Core with Red Jumper to PAS White three pin/White/Black from core with Black jumper to yellow 2 pin
I checked the 8 pin connector again and can’t see that it isn’t making good contact. No bent pins or obstructions.Electric Bike Motor still beeps three times upon connecting to full battery as described with and without full connections of cables.
Yes jumping the two holes as indicated does make the electric bike kit run. It seemed like at first that by moving the controller wire that the electric bike motor would stop and start as if there was a short right at the junction and we thought that might be the problem. We hooked up the cable but I still am not getting any response from either throttle when hooked up to the black two pin connector even if I move the cable at the junction and now using the jumper the short method that issues seems to have gone away?
We are trying hard to make this electric bike kit work here but I have to admit we are getting a bit frustrated. The throttle cable while hooked up shows 5.0 amps on the red wire and from .8 amps at rest and 3.8 amps on the white wire when at full throttle like it should? Without the black pin connector together there are 5.0 amps at the red wire and .1 amps at the white wire if that is any useful information.
Hub motor,electric bike motor,electric bike kit supplier: Leaf Motor Technology Co.,Ltd
Source:https://www.leafmotor.com

Hub motor kit ceased to function

On February 8th we ordered your 26” 48V 1000W front electric bike kit (1 set of 26” 48 1000W hub motor wheel with lcd bldc motor controller,twist throttle,brake levers,48V li battery) which was delivered to us on February 13th.Shipment is very fast.But the packing box is broken,we disconnect it and found the left brake lever was defective and I e-mailed you about getting a replacement set of levers. You told me that the parts would be sent. They never were received. I disconnected the lever plugs and have been using the bike for the past 1 month without them being hooked up.
Last week the bike ceased to function. I have 50+ volts going to the bldc motor controller connection but when I plug in the hub motor controller, the voltage drops to 1.8V and nothing happens. When I disconnect the hub motor connection, the voltage remains at 1.8V. As soon as I disconnect the battery, the electric bike battery shows full voltage of 50+ volts. The voltage indicator lights do not light up at all. So I have good voltage going to the controller but nothing works. I disassembled the controller to see if there was a broken connection or burned out part but can find nothing visibly wrong – when I connect a tester to the board the voltage shows 1.8 when should be 50 at the input connection. Something is wrong internally and I now need the hub motor controller to be replaced. I am relying on the electric bike kit to get to and from work so time is very important to me.
Please send me a new hub motor controller as soon aspossible. Also send me the previously promised brake lever set replacement at the same time (as long as it does not slow down the shipment of the hub motor controller). I would also appreciate it.
Hub motor,bldc motor,electric bike kit 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