Newbie here. Making a 48v5kw winch for snowboarding. Need help!!!

[Degs]

Hello, I am new to this forum and unfortunately I have very little knowledge of electronics and I apologize for my dumb questions in advance.

I am trying to make a rope winch to pull a snowboarder on flat ground using golden Motor parts.  The motor will connected by belt drive to a spool of thin rope (5:1). The operator would pull the rope out when the unit is off and a second operator would depress a foot peddle to wind the rope in. This is a simple idea but I have no idea how to wire this up.  I currently own a 48v/5kw GM motor (HPM05KW-08D-PZ) and a GM controller HPC500 48600. I was looking at purchasing a foot throttle to control the speed but I am wondering how do I wire a foot throttle to the controller? What cables do I require and where can I buy all the parts? I am based in Canada.

ANY help would be greatly appreciated and thank you in advance.

Scott
scott@degeman.com

[Bikemad]

Hi Scott andto the forum.

Gary (Goldenmotor.ca) usually stocks these foot throttles:


Click for more details.

I think these throttles also have an internal switch which (hopefully) could be used to operate the regen function (but you will need to check that the switch contacts are only closed when the throttle is fully released).
This would be useful to stop the spool of rope from continuing to spin due to the inertia after the throttle has been fully released.

Most throttles use three wires to connect to the controller (Red is usually +5v, Black is usually Ground, and Green or White are typically used for the signal wire).
If it does have a switch, there will probably be at least one additional wire (most likely two) which would connect to the brake connection (and a ground connection) on the controller.

You might want to consider fitting a switch to a spring loaded jockey pulley (also wired to the braking function) so that the motor would automatically stop as soon as the tension on the line is lost (someone lets go of the handle etc.)

The contactor switch wire (or the throttle signal wire if a contactor is not fitted) could be wired through a big red STOP button for emergency use:



You would need to either turn off the power to the controller, or fit a breaker switch to the brake wire, to enable the rope to be pulled out again.

You will need to do some calculations to determine the best drum diameter and gear reduction ratio to provide maximum pulling force whilst limiting the maximum rope speed to a safe level. 

Alan