how can I change my internal controller to an external controller

[kmleon77]

hi
how can I change my internal controller to an external controller
never did that before
have you THE explanation I need to do that
any pictures that could help
what am I supposed to get out of the MP and what am I supposed to leave?
want to fix an 40A infineon controller and still want to use cruise control , ebraking and thumb control
what controller do I need to suit the MP that will give a long life to the motor using a 48V10Ah battery
thanks in advance
fred

[Thaialien]

Hi Fred and all
They tell me everything is matched here on Pie Specs are 100% I have never seen Magic Pie wheel spinning !  standard controller (not overvolted and barely enough Amps in battery pack)  with one person on bike ! But have seen video's filmed in Shanghai CHINA  (that's Magic)
Yours does not do this then !
Should be pulling well over 30 amps  (but have never seen it do it)
But its not too hard to change  (but to find 3 thick wires and 5 for the halls will be harder in one multicore ) keep the thick yellow green blue as thick as you can and look for like nylon insulation its tougher and thinner!
(most of the wires are there cut them and solder them on new wires same colour with heatshrink tube and cable tie them neatly to stator casting making sure they don't foul housing of motor  
John L

[kmleon77]

hi
thanks very much then 30A or 35 is enough?
do not when my wheel  spinning but give more power then at the moment
just to get more fun
but have you got any pictures so that I AM SURE I will not make any mistakes
want my MP to have a long life
thanks
fred

[kmleon77]

hi
has nobody open de MP to make such a change?
thanks
fred

[o00scorpion00o]

Yes, and you should really look through the forum or do a search, this has been explained  many times!

But if your battery is a 48volt 10ah LiFeP04, than chances are it will take no more than 15amps max! Maybe 20 amps peak draw, either you will kill your battery or your bms will keep tripping!

This is LiPo territory I'm afraid or very expensive A123 LiFeP04 and a whole different ball game, once you decide to go to a powerful set up it gets a lot more expensive!

But basically you will need to extend the 3 phase wires yellow, green and blue through the axle, along with the 5 smaller hall sensor wires, I used cat 5 and stripped off the insulation. Then I used heatshrink to insulate and make them look tidy! you need to use heat shrink to insulate the joins you make inside the motor.

But you may tell us what type of battery you got first, if it won't do then you are looking at at least 550 U.S Dollars for a LiFeP04 A123 with BMS to be capable of keeping the Pie Happy!


Mark

[kmleon77]

Hi
I have a LiPo 48V10Ah battery
Fred

[o00scorpion00o]

have you more details of the pack?

[e-lmer]

Fred:

I am a bit concerned about this.

It sounds like you do not have a lot of
experience at this kind of hack.

You are modifying a drive train on a
motor vehicle to make something that
goes dangerously fast go even faster.

If something goes wrong you are looking at
Personal injury or worse.

I have made hacks, even re-woven the
 spokes on my wheel, but I have not opened
a pie to make mods, tho I would consider it
if my internal controller failed.

Please consider what your life is worth before
asking strangers, no matter how well intentioned,
to help you do a major hack like this.

[kmleon77]

HI
I do not want to go faster I do  not care about that the pie is enough for me
but more torque is what I am looking for
what do you suggest?
The pie 3 apparently gives 30% torque more but I do not know with what kind of battery yet
except waiting for it what would be your solution to get more torque
thanks
Fred

[e-lmer]

Torque is a trade with speed. 
Smaller wheel diameter gives
more torque an the expense
of top speed.

Torque is force times radius
But you have two torques, one
For the motor, call it Tm,
And one for the tire, call it Tt
(hee hee, t-t)
Your torque is Tm/Tt.

The pi3 gives a higher Tm, so
you get more torque.

A smaller rim increases your torque at the
same power, but there will be danger in
running over speed.

IF I had money and a machinist I trust,
I would add a secondary chain driven
Motor.  Similar to  http://www.ecospeed.com/
But a lower power motor at the correct
voltage to switch in, and not in that location.

(it should freewheel the pedals so they don't go nuts.)

[kmleon77]

ok E-lmer
thanks for the explanation
should a 20Ah battery give more reactivity to the motor instead of a 10Ah both in 48V?
Thanks
Fred

[o00scorpion00o]

ok E-lmer
thanks for the explanation
should a 20Ah battery give more reactivity to the motor instead of a 10Ah both in 48V
thanks
Fred

Are you asking will a 20 ah battery give more power to the motor?

Then yes it will, but most LifeP04 batteries are rated at 1c meaning you should pull only 20 amps max from the pack.

Gm batteries are not a high C rated batteries and they were never meant to supply anything other than GM motors at stock power levels, running 2C would be 40 Amps, and the GM batteries would either trip or the voltage sag would be terrible, or they fail early.

Now you could say the pie will draw max current on hills and acceleration, but the battery still needs to be comfortable in supplying it!

This is why you need high C rated batteries because you can pull a lot more current from a smaller pack.

For instance a 10Ah  pack rated at 10 C would mean you could pull 100 amps continuous from that pack

10Ah x 10 = 100 Amps.

[kmleon77]

thanks
I am learning little by little
fred

[o00scorpion00o]

Hi
I do not want to go faster I do not care about that the pie is enough for me
but more torque is what I am looking for
what do you suggest?
The pie 3 apparently gives 30% more torque but I do not know with what kind of battery yet
except waiting for it what would be your solution to get more torque
thanks
Fred

The pie III has more torque simply because the internal controller is more powerful, it is rated at 35 amps with 60 volts max input that will feel a lot more powerful than pie II but they should supply newer batteries.

The pie III will also be more expensive.

But installing your own controller is fun and the smile on your face at high power is worth it.

You will also need a new throttle and e brake for the new controller.

It's a lot of work but if your pie is working and you have doubts then leave it as it is!

Where do you live? Maybe someone could help you, you need to do a lot of wiring.



Oh yeah thanks for the pics Alan! :-)

[kmleon77]

hello
I am living in france close to coulommiers/seine et marne
but do not know anybody here practicing that knowledge 
but little by little the bird makes its nest
before buying my old house I didn't know anything about how to renew or rebuild anything = and 8 years after everything has been renewed or rebuild and that was hard work
now I can do anything in a house cos learned and did everything by myself exept a few electricity works
"keep on learning fred and next time you will be able to explain anything about motors/controllers/and so on
it's a matter of patience and time
 
fred