Infineon controller for Golden Motor

[MonkeyMagic]

Yipes !

Just when the stats were churning out hope you get it sorted mate

[Electrobent]

All is well:

Edward got back to me with every number.  Turns out that program calls LVC "halt V" and since I did not know what that I was, I did not change it and ended up overwriting it with the default 57 which was one volt more than I had at the time.

Even the highest setting for the ebrake seems less than the default Golden setting.

I was able to set the max regen voltage to 60 (up from 55).

I set the three speeds at 80, 100, and 120% of max. 

That turned out to be fast enough, too fast, and waaay too fast. 

So bottom line:

The Infineon is superior to the cruise controller, and an infineon built with 4110s is a tank.
The program to set the GM controller is a lot more user-friendly but is not as powerful over all.

Next time I do this, I am buying a GM wheel from Gary in Canukastan, another Infineon controller, and probably a Ping battery.

Anybody here replace the bearings in a GM wheel?  I think I am going to get to wear these out!

[MonkeyMagic]

Replacing bearings is straight forward. Don't do it until you really need to though

Is the top speed the same as the GM controller?

Cheers man

[Electrobent]

Much faster than the stock GM cruise controller with factory settings.

I dumbed it down from 80-100-120 to 60-80-100.

I don't even know that 120% is max.  I sort of thought 100% would be but apparently not.

[GM Canada]

Next time I do   this, I am buying a GM wheel from Gary in Canukastan, another Infineon controller, and probably a Ping battery.

Anybody here replace the bearings in a GM wheel?  I think I am going to get to wear these out!

And a proud Canukastanian I am! Is electrobent saying something positive about GM here? Where is my calendar, I have to mark this down

Magzy changed his bearings outside on the patio beside his house, Check this post.

http://goldenmotor.com/SMF/index.php?topic=2632.msg15371#msg15371

Gary

[Gapy]

Hey all...

electrobent can you tell what is the top speed at 120%?

also-did you have any problems geting the wires out the pie (three phase and three halls)?

[Electrobent]

I'll have to get up the guts to try that again with someone following me or my GPS on--and I have a 20 inch wheel.

I have opened Pandora's Box and now my battery is too small and I have increased the probability of hurting myself. 

I have not yet changed out my phase wires but it should not be a problem assuming they fit through the hole in the axle.  Need something with heavy duty but thin insulation.

I am told on ES that the 48V 1KW GM motor can run at 72V 40A with 120 max phase amperage.

[Electrobent]

Ok, I knocked my max amperage to suck from the battery to 25A (from 30), set the max phase current at 74 (only had even numbers--I was looking for 75 to be three times 25).

I set the speeds at 60, 90, and 120

and went out riding with MyTracks running on my HTC Evo.  It must be doing some averaging because its graphs do not reach down to zero and I know I stopped a couple of times. The highest peaks on the graph look like 24 or so but the highest recorded speed was 29.08.  That's with me pedaling as hard as I could in my highest gear and the motor pegged at the 120% max setting.  That's with a 20" wheel.  So if you upped the amperage a tad, you could probably get real close to 38 mph with a 26 inch wheel but you better have nicer roads that we do here in Southern Kalifornia.

It was too dark to do a longer run.  This one was about 6 1/4 miles.  Started at 57.9V, ended at 49.6, rose to 50.1 after pushing the bike in a 100 foot driveway, and rose another .5 V  to 50.6 after sitting for a couple of minutes. 

60 is a pleasant ride, 90 is moving along, 120 is running away from bionic dogs and praying not to hit a pot-hole.

Anyone know how to change the settings on MyTracks to shut off the averaging?

--Eric
 

[Gapy]

I don't think that the wheel size matters-Yao once said that they use different windings for different sizes... not shure tho!

With my internal controller Im doing about 41km/h, hope to boost up to 50 with infenion! (should be here soon )

electrobent: can you tell me what kind of switch do you have for speed settings and where it is connected-I forgot to order the damn switch!

[Bikemad]

I don't think that the wheel size matters-Yao once said that they use different windings for different sizes... not shure tho!

What Yao actually said was:

You might find it strange, however the 16" is made to hit that speed. The windings are different, lower torque but higher speed. Go check out the Tq figs for the 16" and you shall understand!

I suspect this speed increase has simply been achieved by using Delta winding configuration instead of Star, and I'm pretty sure that the increased wheel speed is only relevent to the 16" cast Magic Pies.

The 20" wheel that Eric (Electrobent) is using is fitted with an HBS hubmotor:

These motors already have a higher RPM than the standard Magic Pies, but it would be interesting to see if the Infineon controller does actually produce a faster unloaded wheel speed, or whether it's simply able to spin the wheel faster against the same load because of the extra Amps being delivered.

Alan
 

[Electrobent]

its just a three position rocker marked "I" "II" "III",  the schematic is amongst the wealth of technical information about the controller that is available here:   http://endless-sphere.com/forums/viewtopic.php?f=16&t=7361

[Electrobent]

I was able to to do my loop at 90% on the 25A setting.  58.5 V to start. 48.5V 9 miles and 1200 feet up later.  49.5V once back home.  I am really liking the throttle regen:  it lets you feather the amount of braking and you can find a sweat spot where you can't really feel it but you are ever so slightly charging. It also makes for less harsh braking.  The ebrake is better than the two rim brakes. Max speed at 90% speed is about 25 mph, 120% 30 mph.  I think I had my old GM 36V 500W setup going 36 once.  Things start to get a little hairy above 25 mph on all but the very newest of roads.

My controller and my wheel can handle far more current than I have battery to accommodate.   I guess I'll add it my other 24V and see how that is.  Have to modify the Infineon board to get the regen to work above 60.  The mod involves changing out a surface mount resistor.  I am glad I know someone who has done that before!

I think it would take about $4K US worth of batteries to really work this controller-hub combination.

[o00scorpion00o]

I was able to to do my loop at 90% on the 25A setting.  58.5 V to start. 48.5V 9 miles and 1200 feet up later.  49.5V once back home.  I am really liking the throttle regen:  it lets you feather the amount of braking and you can find a sweat spot where you can't really feel it but you are ever so slightly charging. It also makes for less harsh braking.  The ebrake is better than the two rim brakes. Max speed at 90% speed is about 25 mph, 120% 30 mph.  I think I had my old GM 36V 500W setup going 36 once.  Things start to get a little hairy above 25 mph on all but the very newest of roads.

My controller and my wheel can handle far more current than I have battery to accommodate.   I guess I'll add it my other 24V and see how that is.  Have to modify the Infineon board to get the regen to work above 60.  The mod involves changing out a surface mount resistor.  I am glad I know someone who has done that before!

I think it would take about $4K US worth of batteries to really work this controller-hub combination.

Sorry to dig up an old thread, but if you want batteries that can handle such power then you need LiPo and Endless-sphere is the place to study.

If you are not familiar with LiPo, it's not as easy as plug and play and you don't have a bms, but you can fast charge some of them up to 30 amps+. And discharge up to 40C which is much more than required for an E-Bike. The zippy LiPos are good price. I have ordered 4 x 6S 8ah. And I will make either a 44 volt 8 ah for short trips, or 16 ah for longer trips.

You can make a cheap enough LiPo pack, but the charger and power supply will cost, depending on how fast you want to charge, but it should be seen as a long term investment and should last many  years! you also need cell monitors that sound an alarm on cell low voltage.

There  are also high C rated ready built LiFeP04 packs, but are very expensive.

Another thing with LiP0 it can cause fire if abused, either charging or discharging, and you usually have to split the pack up to charge in parallel.


Mark

[DirtyGinge]

Hi Mark

Did you mention li-po ?

Where did you get yours, pricing etc ?

Cheers buddy

[o00scorpion00o]

Hey dinge,

I got my LiPo from Hobby King in the U.S

I got 4x 8S 8AH Zippy Lipo cost $430.00 inc shipping!

The advantage to me is it's light, and I can split the pack in half depending on if I want lots of exercise or fun!

A ping 48V 15 AH costs 594 inc shipping, ping 1C Zippy 30 C 


Mark