In this topic, we are trying to understand the working of Electric Bike Controller Circuit Diagram Controller in E-bike. In an e-bike, it doesn’t mean that motor and battery that’s all. There is a third party involved in this to manage them and they work correctly. This is only possible by somehow programming and hardware skills with the help of a controller. Now we are designed a controller for this to control the motor of the bike. The main or we can say the core feature of this controller is to manage the DC Motor that runs smoothly. Many motors are controlled by hall sensors that are responsible for the power consumed. Now a day we need a motor running smoothly beside this, we need throttle, motor, and battery. If you want these things to run perfectly then make sure you are using the controller. Now we are designing such type of controller that will responsible for all. This controller senses the setting of the throttle and adjusts the power supply to the motor. For all these things we are using the Pulse-width Modulation technique. We will discuss this later. Now we discuss the other functionalities of the controller that we are making such like Voltage Cutoff Switch We are using a cutoff switch that is responsible for the voltage supply from the battery. The cutoff switch cut the connection if the voltage drops to the motor. This help to protect the battery from over-discharge. Temperature Cutoff Switch This cutoff switch is used for temperature monitoring of field-effect power transistors. It will cut the power supply of the motor if the FET power Transistors are overheated. Current overflow cutoff This cutoff switch manages the current supply to the motor and the field-effect power transistor. In case of the over current is supplied to the motor and field-effect power transistor, it will cut the power supply for the protection of the motor and field-effect transistor. Supply cutoff switch This cutoff switch helps to manage the motor and no waste of current. It cut the supply to the motor when you apply brakes. This is only for safety purposes. Safety note This is an advanced-level project. Do not try to attempt this if you don’t have only experience with electronic devices. In this project we are playing with current and voltage, it is dangerous and difficult to handle, so plz do it under the supervene of experienced persons. If you are using a 48-volt power supply then you have to use 12 volts power supply for the controller. If you are using 12 volts cell pack then simply tap 12 volts from the pack. In my case, it is impossible for me, so I am using 12 volts power supply or you can convert DC to a DC converter to supply 12 volts of power. The controller that we are making is designed for this e-Bike. We are using IRFP4468 field-effect power transistors are rated at 195 Amps at 100 volts maximum. This E-bike uses a very small amount of Amps like 10 Amps at 50 volts. It was tested around about 10 miles every day and this controller is tested and trouble-free. List of items all the things are mentioned there but a few things are used Prototype Board Heat shrink tubes few screws few insulation padding an enclosure Assembling section you can design this layout by cad program. Schematic drawing Code /*************************************************************************** A simple DC motor controller This program implements the following functions a startup throttle limit checks b read the throttle and set the PWM duty cycle It should also check c the maximum allowed motor current d low battery voltage e low battery voltage but these checks c,d,e are not implemented yet. Chip type ATmega8-16 Clock frequency MHz ***************************************************************************/ include include include include include include include include include include define ADC_VREF_TYPE 0x40 unsigned char pwx; // pulse width unsigned char j = 0; // LED value unsigned char i = 0; // loop counter // Read the AD conversion result unsigned int read_adcunsigned char adc_input { ADMUX = adc_input ADC_VREF_TYPE & 0xff; // Start the AD conversion ADCSRA = 0x40; // Wait for the AD conversion to complete while ADCSRA & 0x10 == 0; ADCSRA = 0x10; return ADCW; } // Timer 1 overflow interrupt service routine ISR TIMER1_OVF_vect { OCR1AL = pwx; // set the pulse width } int mainvoid { int throttle; // Port B initialization not used // Func7=In Func6=In Func5=In Func4=In Func3=In Func2=In Func1=Out Func0=Out // State7=T State6=T State5=T State4=T State3=T State2=T State1=0 State0=T PORTB = 0x00; DDRB = 0x02; // Port C initialization not used // Func6=In Func5=In Func4=In Func3=In Func2=In Func1=In Func0=In // State6=T State5=T State4=T State3=T State2=T State1=T State0=T PORTC = 0x00; DDRC = 0x00; // Port D initialization used for simple LED toggle // Func7=In Func6=In Func5=In Func4=In Func3=In Func2=In Func1=In Func0=In // State7=T State6=T State5=T State4=T State3=T State2=T State1=T State0=T PORTD = 0x00; DDRD = 0x04; // Timer/Counter 0 initialization // Clock source System Clock // Clock value Timer 0 Stopped TCCR0 = 0x00; TCNT0 = 0x00; // Timer/Counter 1 initialization // // TCCR1A // COM1A1 COM1A0 COM1B1 COM1B0 FOC1A FOC1B WGM11 WGM10 // // TCCR1B // ICNC1 ICES1 -– WGM13 WGM12 CS12 CS11 CS10 // // Clock source System Clock // Clock value kHz // Mode Fast PWM top=03FFh // OC1A output Non-Inv // OC1B output Discon // Noise Canceler Off // Input Capture on Falling Edge // Timer 1 Overflow Interrupt On // Input Capture Interrupt Off // Compare A Match Interrupt Off // Compare B Match Interrupt Off TCCR1A = 0x82; TCCR1B = 0x19; TCNT1H = 0x00; TCNT1L = 0x00; ICR1H = 0x00; ICR1L = 0x3F; OCR1AH = 0x00; OCR1AL = 0x00; OCR1BH = 0x00; OCR1BL = 0x00; // Timer/Counter 2 initialization // Clock source System Clock // Clock value Timer 2 Stopped // Mode Normal top=FFh // OC2 output Disconnected ASSR = 0x00; TCCR2 = 0x00; TCNT2 = 0x00; OCR2 = 0x00; // External Interrupts initialization // INT0 Off // INT1 Off MCUCR = 0x00; // Timers/Counters Interrupts initialization TIMSK = 0x04; // USART initialization // Communication Parameters 8 Data, 1 Stop, No Parity // USART Receiver On // USART Transmitter On // USART Mode Asynchronous // USART Baud rate 115200 Double Speed Mode UCSRA = 0x02; UCSRB = 0x18; UCSRC = 0x86; UBRRH = 0x00; UBRRL = 0x07; // Analog Comparator initialization // Analog Comparator Off // Analog Comparator Input Capture by Timer/Counter 1 Off ACSR = 0x80; SFIOR = 0x00; // ADC initialization // ADC Clock frequency kHz // ADC Voltage Reference AVCC pin ADMUX = ADC_VREF_TYPE & 0xff; ADCSRA = 0x85; // Global enable interrupts sei; while 1 { // read the throttle position throttle = read_adc0; // toggle the LED if i == 255 { i = 0; j = j ^ 0xff; PORTD = j; } i++; // If the ADC reads out of normal range then assume that the // throttle is either disconnected, or not connected properly if throttle 1000 { // disable the PWM output // and cut the throttle TCCR1A = 0x02; throttle = 0; } else { if throttle > 1; } if throttle > 1023 throttle = 1023; } pwx = throttle >> 4; } }