GoldenMotor.com Forum
General Category => General Discussions => Topic started by: Perbear on February 07, 2009, 12:11:57 PM
-
In Europe an e-bike must be of the electric motor assist type, pedelec, to be road legal without registration. This means it must follow the requirements in directive 2002/24/EEC. Pedelecs that follow european requirements has been given it's own name: EPAC.
To be an EPAC, or EU-legal pedelec, the e-bike must follow these rules:
- Continous motor output is maximum 250W
- Motor can only assist when pedals are being used to pedal, i.e. moving in "forward" direction
- Motor output must gradually be reduced to zero when the e-bike approach a speed of 25 km/h
- Motor output must stop when brakes are used
In the new product safety standard for EPAC, EN 15194, there are a few other requirements that is important. The EN 15194 will be released April 1, but it is likely that it does not contain major changes compared to the preliminary version prEN 15194. Assuming there are no major changes the following from prEN 15194 should be added to the basic requirement list above:
- Maximum system voltage is 48V
- Maximum weight is 40 kg
- Limit on maximum brake length using both brakes and only rear brake in wet and dry conditions
- Specific requirements on parts that may contribute to starting a fire (battery and charger related parts)
For our DIY community it is important to notice that there is no requirement for a fixed ratio between motor power and pedal power. This is a requirement in Japan, but not in Europe. That means we do not need pedal torque/force sensors.
For the manufacturers of complete EPAC and conversion kits there is one new requirement that will be important:
- EMC testing will be required for complete EPAC and kits ???
The only real challenge I see when using GM parts for making your own EPAC is how to control the gradually reduction of motor power when we approach 25 km/h. I believe the easiest is to use the BAC-28x cruise controller but I don't know how.
Does anyone have enough knowledge on the BAC-28x to accomplish this?
Thanks,
Per
-
hi Perbear,
Do you agree with me that the european rules are ridiculous ?, they make electric bikes almost pointless.
I want the start a petition to have the laws changed - are you interested?
-
hi Perbear,
Do you agree with me that the european rules are ridiculous ?, they make electric bikes almost pointless.
I want the start a petition to have the laws changed - are you interested?
Hi Philip,
I shared your view a while back, but after studying the rules and standards, I now understand the reasons for these limitations. First, all motorized vehicles used on public roads has regulations, the same with EPAC. And remember that within these limitation we can use our e-bike as a regular bike, with no extra insurance, protection, traffic regulations etc. That is a huge benefit.
Remember also that the EPAC is a cycle with motor assistance. The motor is not to give you a speed on the flats higher than other cyclists. You normally only need the motor when going uphill, against heavy wind, or when you are tired. Then the 25km/h is an acceptable limit. Also, as I explain below, the limits can be tweaked, both speed and most important, the 250W limit. IMHO, the EN 15194 standard actually gives wider limits for EPAC speed and power than the 2002/24/EEC directive alone:
1) The EN 15194 standard accepts a 10% "production" deviation on speed limit: "During a production conformity check, the maximum speed may differ by ± 10% from the above-mentioned determined value.". With accurate speed sensor (+/- 0.5 km/h), you may set the limit at 27 km/h and still be legal. :)
2) 250W limit is for continous motor output. If your motor is bigger, say 300W but this is power INPUT, not output, and it's maximum efficiency is say 80%, this would be a legal motor for EPAC. :D
3) EN 15194 specifies motor power to be measured according to EN 60034-1 section 3.2.1 duty type S1 - continous duty cycle. (Actually, this chapter does not exist, so this is obviously a misprint for 4.2.1).
The chapter in EN 60034-1 about duty cycle S1 describes how to find the load (output power) the motor can handle continously this way: "Operation at a constant load maintained for sufficient time to allow the machine to reach thermal equilibrium..".
That means the 250W limit is the power output the motor can supply continously without burning the motor windings. Power output can actually be more than 250W for limited periods.. ;D
That means you may have a motor with 500W or 1kW peak output for hill climbing as long as your motor can not handle the higher peak power for more than a limitied time without overheating the windings. The peak power must be limited/controlled by temperature sensors or other means. The maximum speed must of course not be exeeded even at peak power.
As a last resort, you may use a more powerful/faster e-bike than EPAC in Europe, but it is much harder to make it yourself since it must be approved/MOT and have insurance.
Per
-
Hi Per,
Thanks for the information of EU regulations for ebikes. We will make necessary enhancements to let our products to meet these rules.
We are also modifying our battery casing and plugs to replace existing kettle style plugs which are illeagal in EU as reported by a member of this forum.
Thanks for all members and readers of this forum, who help us improving our products quality by sending us feedbacks and advices.
We are going to setup dealers network in EU and USA so we can lower the shipping cost significantly and provide local logistics and services locally. You are all welcome to become our local dealers if you are interested in such business partnersship. We are confident that personal electric vehicles will be huge profitable business in coming years.
Thanks for all your support and tolerance.
Philip Yao
President
GoldenMotor.com is ranked at top positions by Google for following product keywords:
------------------------------------------------------------------------------------
ebike motor
bike conversion kit
electric bike motor
hub motor
brushless motor
brushless controller
wheelchair motor
......
-
Hi Philip Yao,
Thanks for your kind words :)
In March I will start a course about building e-bikes here in Norway. Many participants are less than 18 years. So I have to be 100% certain that the bikes we build will both be safe and completely legal. Because of that I have spent a lot of money and many hours getting hold of the necessary standards and studying them. So if you need input on how to make EU compatible kit/parts please let me know. I will be glad if I can help.
Currently we need a controller that can reduce motor power gradually when bicycle speed comes close to max speed (25-27 km/h). Maybe your new BAC-28X series controller fixes this?
Kind regards,
Per
Visit www.evs24.org (http://www.evs24.org)!
-
The EN 15194 standard has now been accepted in all 30 countries responsible for this CEN based standard. A schedule for implementation can be found here:
http://www.bike-eu.com/news/3260/time-table-for-epac-standard-implementation.html (http://www.bike-eu.com/news/3260/time-table-for-epac-standard-implementation.html)
Please observe that this is a product standard for Manufacturers and it is not a requirement for homemade DIY e-bike, only for readymade e-bikes and e-bike parts.
Per
-
Per;
I am an e-bike advocate here in the US.
I would love the chance to review your materials
for your class, and if you allow, even use them.
Thanks;
Duane
-
Hi Duane,
I have sendt you PM.
Per
-
I just want to summerise to get this straight:
1. Do we need to mount the Pedalec switch in EU ?
2. We need a controller that reduces the motorsupport over 25km/h ?
/Marc- Bergneustadt Germany
-
1. Do we need to mount the Pedalec switch in EU ?
According to EU directive 2002/24-EU you need to make sure that the motor only runs when pedaling. Lacking the Pedelec sensor is very easy to prove for official persons like police etc. This can be controlled very easily, even when the cycle is locked. IMHO it is stupid not to install pedelec sensor on European ebikes. :o
2. We need a controller that reduces the motorsupport over 25km/h ?
This is also mandatory according to the EU directive mentioned above. But: all legal ebikes in EU need the cyclist to be pedaling to allow the motor to run. How shall other persons know if it is you alone, or you+motor who makes it go so fast when you pass by at 30 km/h? Of course, a noisy motor will be suspicious, but a 250W direct driven hub motor is almost impossible to hear. The only way to prove such a ebike is illegal would be to test the ebike at a rather complicated testbench. In addition, the new EN 15194 Pedelec (EPAC) standard allows +/- 10% production tolerance on the 25km/h speed limit, giving a 27.5 km/h practical limit. That means you need to go much faster before some official guy will do all the work necessary to prove your ebike is illegal. IMHO it is unlikely that someone want to collect enough data to prove you have a motor going faster than the Pedelec limit, within reasonable limits. A 250-500W direct driven hub motor should in my view be quite safe as long as it is impossble to prove without physical testing. Remove the label if it states higher power than 250W. ;D
Perbear
-
1. I'm not getting the pedalec to work :(
2. So we need a pulse switch on the pedelec that can switch Pin7 over X pulses....it's quicker to make something like that our selves...
-
In fact this is why I think it may be a good idea to register and inspect even low power, especially DIY vehicles, and to base the vehicles classification on the results of inspection or official police traffic stop data in addition to component specifications rather than on anything else.
I can understand that view in the US where some states does not limit power on ebikes. Sooner or later an accident, caused by underpowered brakes etc., will happen. That may cause politicans to put a ban on homemade ebikes. It is better to work out some regulation now, instead of overcompensated regulation made by people in panic.
In the EU (plus Norway and Island), some basic common ebike rules has been agreed upon in 2002. It is basically a definition of a legal "line". Bikes with electric motor acting as an assistant to the cyclist one one side, and electric mopeds, motorcycles, minicars etc. on the other. The benefit of being on the assisted ebike side - or EPAC as they are named in EU, is that they are considered to be normal bikes legally.
To be an EPAC your ebike motor may not apply power to the wheel when you go faster than 27.5 km/h (25 km/h + 10% tolerance). The motor must also supply not more than 250W continous power output to the wheel. In addition, the motor can only run when the pedals are used and must gradually reduce its contribution to forward motion when the speed approaches the maximum ebike speed. Also, the motor must stop when the cyclist applies the brake.
An ebike following these limitations is considered an EPAC and is legally a bicycle. That means they can be used everywhere bikes are allowed and does not require insurance, license plates, driving license or type approval. If your ebike does not have a brake or pedal sensor or have a motor that supplies more than 250W continously your ebike is no longer a bicycle in Europe and may not be allowed on the street without type approval, etc. It will also be illegal to use on cycle paths.
I think the sensor requirements are fairly well thought out, but the speed and power limit is somewhat limiting for some uses. I hope for the future that European legislation will add two enhanced EPAC classes where your motor could assist either 250W without speed limitation (for velomobiles), or 1000W with 25 km/h speed limitation (for hill climbing). Complying to one of these classes could require putting an insurance sticker on your bike, and also an age limit.
IMHO Per
-
The new pedelec (EPAC) standard EN 15194:2009 is now available for purchase in Europe.
I bought my copy a week ago and have just finished reading it. It is basically identical to the prEN 15194:2005 with some minor modifications.
Per
-
Link to a preview of the first seven pages of EN 15194:2009 http://www.bike-eu.com/public/file/archive/20090428-epac_standard_en-15194_preview.pdf (http://www.bike-eu.com/public/file/archive/20090428-epac_standard_en-15194_preview.pdf)
-
A public standard you have to purchase??? Absurd! In fact all law making bodies should pass a law that requires them to publish every law, rule and regulation in the form of a checklist with mandatory updates when new variables are added by case law or new legislation.
That is simply not the way standardisation work is done. Sorry :'(
But you have the possiblity of becoming a member of your own Country's IEC standardisation comittee. That way you will help deciding future standards. In addition you will receive drafts and final standards you contribute to for free ;)
-
I have now built two ebikes with GM parts, the latest using the BAC-28X series controller. I have also helped several others assembling ebikes here in Europe. Unfortunately, the controller is not suitable for a legal European ebike (EPAC) as it works now. Here are the two most important issues:
- Pedal usage sensor (Pedelec) only works when manually enabled - it should automatically be working when powering up
- Throttle overrides the pedelec sensor - it should be the other way - throttle should only work when pedaling if connected
These two important issues needs to be fixed to be able to present a GM based ebike as a legal EPAC in Europe.
In addition, the following issues should be improved somehow:
- The current pedelec sensor function uses cadence (pedal RPM) to control motor power - this is a bad solution. The ebike speed varies from the cadence dependent on gears selected so the current pedelec function may only work on single speed bikes - if it can work well at all
- A good solution would be to use a torque sensor as an optional man/machine interface (similar to what is required in the Japanese Pedelec standard)
- There should be a settable maximum speed for the controller with full power, and a settable speed for minimum power. Currently, the 250W mini motor runs faster than allowed (35 km/h with 700c wheels)
- EN 15194:2009 allows a startup mode that can activate motor without pedaling at max speed of 6 km/h. This function must be manually selected by a separate button/handle. This function would be nice to have and is currently missing.
- The brake switches are only required if pedal sensor is slow to react. If user stop pedaling and power to motor is cut before ebike has moved more than 2m no brake switches are required. This would require a better/faster pedelec sensor, but would make it possble to use original brake handles
There are also other issues related to EN 15194:2009 like IP X4 water protection, 90 cm drop test on battery and tough EMC immunity requirements. Fortunately, when the EN standard will come into force in July this year it will make a much larger market for EPAC ebike parts.
Per
-
Hi Philip Yao,
Thanks for your kind words :)
In March I will start a course about building e-bikes here in Norway. Many participants are less than 18 years. So I have to be 100% certain that the bikes we build will both be safe and completely legal. Because of that I have spent a lot of money and many hours getting hold of the necessary standards and studying them. So if you need input on how to make EU compatible kit/parts please let me know. I will be glad if I can help.
Currently we need a controller that can reduce motor power gradually when bicycle speed comes close to max speed (25-27 km/h). Maybe your new BAC-28X series controller fixes this?
Kind regards,
Per
Visit www.evs24.org (http://www.evs24.org)!
Yes per, our controller fixes this problem. If you have any questions at all, feel free to mail me.
Yao Yuan
yaoyuan@goldenmotor.com
-
Per,
I am in the UK and there is a local law which slightly conflicts with European Law.
Do you know if it is clear that European Law takes precedence above national rules?
Thanks,
jb
-
Per,
I am in the UK and there is a local law which slightly conflicts with European Law.
Do you know if it is clear that European Law takes precedence above national rules?
Thanks,
jb
According to the article http://www.bike-eu.com/facts-figures/eu-regulations/3359/new-epac-standard-for-safe-e-bikes.html (http://www.bike-eu.com/facts-figures/eu-regulations/3359/new-epac-standard-for-safe-e-bikes.html) :
Sixth months after the EPAC standard announcement all the European and EFTA National Standards Bodies will have implemented the EPAC standard as national standard and any previous national standards shall be withdrawn before this date. This date is July 31st 2009. The implementation of the EPAC standard varies by country. In some European countries it is compulsory by law. These countries are (as far as Bike Europe knows at this moment) France and the UK. In other countries it is part of the European product safety ruling.
As I understand this it seems that all UK EPACs (Pedelec in EU terms) that is produced or imported after July 31. 2009 must follow EN 15194.
Per
-
To be an EPAC your ebike motor may not apply power to the wheel when you go faster than 27.5 km/h (25 km/h + 10% tolerance). The motor must also supply not more than 250W continous power output to the wheel. In addition, the motor can only run when the pedals are used and must gradually reduce its contribution to forward motion when the speed approaches the maximum ebike speed. Also, the motor must stop when the cyclist applies the brake.
I think the motor is gradually reducing its torque when speed increases, so no action from controller needed for that. Just stop the motor at abt. 27.5 is needed. Also brake switches are not needed if motor stops when not pedaling. Speed can be controlled by gas throttle if you pedal, no matter how fast.
For DIY everything should be kept in KISS design, but still according to EU-legislation.
-
The reason for the brake switches is the requirement to be able to stop the motor before the bike have moved more than 2 m after pedaling stops. If you have brake switches your motor can continue to run until you have moved 5 m after you have stopped pedaling. When you stop pedaling the motor should stop immediately. If it does that before the bike has moved 2 m after pedlaing stops, brake switches are not required.
I suggest that the PAS magnet wheel is supplied with many more magnets (or made of punched steel with plenty "fingers" that can be sensed) to have a much better resolution/response. This is required so that the PAS senses immediately when you start or stop pedaling. I can not see any good reason for coupling the pedaling speed (cadence) to the motor speed or torque as it is done now.
It is important that the throttle only work when you pedal, if not, the ebike would not be according to EN 15194. Also, the PAS must be working as default and not as it is now where you have to switch on the PAS function every time you start the bike.
In addition, GM should add start-up mode (bike can go up to 6 km/h without pedaling) but that would require an extra switch input.
-
Perhaps if there was a simple micro-switch, reed-switch or optic sensor that activated each time the pedal arms completed a revolution? Would it perhaps be possible to use a 555 timer circuit that kept power to the controller as long as 2 seconds? That way you only need to do a revolution of the pedals every 2 seconds to keep the controller turned on, if you stop pedaling then the controller turns off in 2 seconds. Just a microswitch a simple 555 timer with a relay that go's to the controller, perhaps to the brake switch. It's a kinda grey area to give e-bike builders an easy loophole around the new law with no need to add expensive complicated circuits. ::)
-
Perhaps if there was a simple micro-switch, reed-switch or optic sensor that activated each time the pedal arms completed a revolution?
The EN 15194 requires that the motor stops before the bike has rolled more than 2 m after pedaling stops, and not 2 seconds or alternatively one revolution of the krank. This requirement makes it a bit more complicated.
I forsee a simple microcontroller board with sensor inputs for the following:
Speed sensor (inductive with one pulse per spoke passing by),
pedal sensor (with 16 or more pulses per revolution that discriminate direction of rotation),
current sensor (to limit max current),
hand/thumb throttle
The output should be the speed input to the controller plus four LEDs (power, power reduction at over current, power reduction at near speed limit, power off due to maximum speed).
The board should have a single switch input used for activating startup-mode (up to 6 km/h without pedaling) in normal usage. If the switch is kept pressed during power-on, the board LEDs become diagnostic LEDs for the sensor inputs (one for speed sensor signal, one for pedal sensor, one for current sensor and one for throttle input - the last two has flashing speed dependent on input value)
The board should be easy to reprogram by user/owner to customize for various wheel sizes, battery current sensors and speed limits (when to start to reduce power, and when to cut power).
Throttle speed ramp-up should also be tunable by user to have the bike behave smooth in various circumstances; imagine when speed signal to controller has been turned off due to stop of pedaling, and the user start pedaling again - the motor must not be activated abruptly. Also for regenerative braking is smooth handling very important.
Does anyone feel the need to make such a microcontroller board? :P
-
Hi Perbear,
I have a question for you if you don't mind - do you think an ebike would be considered legal under european rules if it had 2 x 250W motors i.e. one on the front and one on back?,
This would allow the bike to climb hills and accelerate better without allowing the bike to reach 'high' speeds.
I have built a bike with 2 motors controlled by one throttle and two controllers it's quite straight forward.
Thanks
-
Hi Perbear,
I have a question for you if you don't mind - do you think an ebike would be considered legal under european rules if it had 2 x 250W motors i.e. one on the front and one on back?,
Philip,
The max power is specified to 250W continous rated power. It is in some sections specified as motor power but in the major definitions like Scope in section 1 and in the power measurement appendix D.1 the reference is to "output power" of the cycle. Using two motors will not allow doubling the cycles output power.
But:
The EN 15194:2009 states the following definition in section 3.22 of Continous rated power: "Continous (or constant) output power specified by the manufacturer, at which the motor reaches its thermal equilibrium at given ambient conditions". In a different section the thermal equilibrium is when the temperature in the motor does not change more than 2K in an hour.
With suitable electronics it should be possible to use the thermal mass inside the motor for having extra peak/burst output power without added complexity and weight from using two motors. This can be used together with a tilt sensor or a power boost button, typically for going uphill. As long as you have a thermal sensor or something that reduces power to the motor when it comes close to the max temperature, it would be OK. But remember that your system must automatically reduce power to zero when reaching 25 km/h to be legal.
-
Thanks Per,
It think your saying 2 x 250W motors would not be legal, this is a pity because the characteristics of hub motors mean that 2 x 250W motors would have more or less the same top speed as 1 x 250W while still having greater acceleration.
Would you agree that the californian rules are more realistic than the EU ones?, in California they can have 1000W motors a top speed of 35km/h and no requirement to pedal.
If it's good enough for California, China and probably other countries why can't we do it in europe ? - you may have more insight into this as you have a copy of the standard
- I personally believe europe does not want to lose tax revenues for all of the two-stroke scooters that could be taken off the streets if proper e-bikes were allowed
-
- I personally believe europe does not want to lose tax revenues for all of the two-stroke scooters that could be taken off the streets if proper e-bikes were allowed
I agree. There is no other logical explanation why the power is limited to only 250W but to prevent loosing tax income. Maybe we should start our own EPAC EU-lobby? ;)
-
Hey guys,
i am from Australia and the laws here only allow 200w max motors. What many Aussie e bikers are doning is putting 500w motors on their bike and taking the rist with the law.... most police here as I would assume the same in europe do not have the tools to test how powerful the motor is.... if I was u I would ignore the laws and build a bike that can get u up hills with ease and respect the speed limit... I cannot see that the police would have the time to check every bike that has a motor just to give a stupid fine.
anyway just thought I would make comment about unjust regulations that are preventing people from using alternative green power transport.
cheers.
-
I am serious about ebikes and will start a lobby, I would imagine it would take years to make any changes though as the EU rules have just been set,
Per, do you know how to go about lobbying the government ?,
Architect, I have a 1000W motor in Ireland where the limit is 250W and have not been called up on it by the police (yet), I want to change the laws because I think the laws not reasonable, I don't like the feeling of always being wary of seeing cops and I would like to sell ebikes and can't see a very big market for the legal models.
-
I don't thik there is any laws or regulations in any of the countries that say you can not build an e-bike with motor greater than 200W, 250W or 750W.
You just have to treat them as motorcycles and abide by the appropriate regulations.
Off read there is no limit in any country.
I don't what people on e-bike going 30 plus MPH on our peaceful bike trails.
The limits are all about safety and creating a class of vehicle.
-
There exists certain bikes and usages where the current EN standard is not suitable, like velomobiles and delivery bikes and racing.
IMHO it should be possible to extend EN 15194 to for these vehicles and practices or at least make it possible to go beyond either the speed limit (for example velomobiles can easily go much faster than 25 km/h with only 250W) or power limit (delivery bikes would benefit from more power than 250W and at the same time be limitied to 25 km/h and still be quite useful and very "green" transport). This would not increase risk since velomobiles have quite a high speed from human power already, it is only limited when going uphill. The risk associated with delivery bikes would not be increased either as long as the speed is limited to 25 km/h. A simple liability insurance sticker could be an acceptable requirement for these "limited by one, but not the other" class vehicles.
For racing it should be allowed to use more power and higher speed but that will come when ebike racng becomes more common 8)