Brushless motor doesn't run under load

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br549
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Last seen: 10 years 2 months ago
Joined: Sunday, January 24, 2010 - 15:03
Points: 4
Brushless motor doesn't run under load

Symptom: Motor doesn't have any power under load.

Specs:
Motor is the Original Etek brushless motor purchased directly from Briggs and Stratton.

Motor Controller
------------------------------------------------------
1 x Controlbox () = $39.00
1 x Throttle Hall 0-5V Twist Grip(WUXING) () = $19.00
1 x Assembly with Reversing(KD) () = $229.00
1 x KBLI Optional Waterproof () = $58.00
1 x Meter LED 72Volt State of Charge () = $19.00
1 x KBL72301,24-72V,300A,BLDC Controller/With Regen () = $549.00
1 x HWC1B Series 72V/8A Charger () = $199.00
1 x HWZ Series DC/DC Convertor 72V to 12V 300W () = $129.00
1 x Amperemeter 400A () = $29.00
1 x Kelly RS232 Converter and Cable and Standard USB to RS232 () = $39.00
------------------------------------------------------
Sub-Total: $1,309.00
Table Rate (Best Way): $163.00
Total: $1,472.00
http://www.newkellycontroller.com/product_info.php?cPath=23_46&products_id=263
I got the assembly so I wouldn't have a problem wiring it up (this is my first try at this).
http://www.newkellycontroller.com/product_info.php?cPath=30&products_id=333
I also got the controller box.
http://www.newkellycontroller.com/product_info.php?cPath=36&products_id=131

Troubleshooting:
I tried all 36 combinations per this thread (great thread by the way). I couldn't have gotten this far without it.
http://endless-sphere.com/forums/viewtopic.php?f=16&t=3484&start=0
When I try the motor under no load on the bench it sounds and runs great.
Symptom: Motor doesn't have any power under load.

Specs:
Motor is the Original Etek brushless motor purchased directly from Briggs and Stratton.

Motor Controller
------------------------------------------------------
1 x Controlbox () = $39.00
1 x Throttle Hall 0-5V Twist Grip(WUXING) () = $19.00
1 x Assembly with Reversing(KD) () = $229.00
1 x KBLI Optional Waterproof () = $58.00
1 x Meter LED 72Volt State of Charge () = $19.00
1 x KBL72301,24-72V,300A,BLDC Controller/With Regen () = $549.00
1 x HWC1B Series 72V/8A Charger () = $199.00
1 x HWZ Series DC/DC Convertor 72V to 12V 300W () = $129.00
1 x Amperemeter 400A () = $29.00
1 x Kelly RS232 Converter and Cable and Standard USB to RS232 () = $39.00
------------------------------------------------------
Sub-Total: $1,309.00
Table Rate (Best Way): $163.00
Total: $1,472.00
http://www.newkellycontroller.com/product_info.php?cPath=23_46&products_id=263
I got the assembly so I wouldn't have a problem wiring it up (this is my first try at this).
http://www.newkellycontroller.com/product_info.php?cPath=30&products_id=333
I also got the controller box.
http://www.newkellycontroller.com/product_info.php?cPath=36&products_id=131

Troubleshooting:
I tried all 36 combinations per this thread (great thread by the way). I couldn't have gotten this far without it.
http://endless-sphere.com/forums/viewtopic.php?f=16&t=3484&start=0
When I try the motor under no load on the bench it sounds and runs great.
http://www.youtube.com/watch?v=-16TluHidqQ
With regen
http://www.youtube.com/watch?v=EEJZXapDXDU

When I hook it up on the trike it makes a little popping sound like it's missing. I have a couple of combinations that work good on the bench but not under load.
Wheels up
http://www.youtube.com/watch?v=VP4RykMsezM
Wheels down
http://www.youtube.com/watch?v=8BWOCszStMc

Under full load it has no power. :(

When I check the hall sensors they each cycle up and down and show 4.48 volts.
When I spin the tires manually and check the hall sensors I've never seen all three showing voltage at once so I'm pretty sure it's set properly at 120 degrees.
Power wire is 4.89 volts.
Phase wires start out at 1.7 volts or so and each cycle up and down with power. I've had it up to 6 volts and the wheels spin faster than I want to chance it while having it up off the ground with no load.
I'm using all the software defaults on the controller. I did try regen and on my last test I disabled the auto temperature shutdown sensor for the motor (since I didn't have it hooked up).
http://www.newkellycontroller.com/KBLHelp.php

Resolution:
I feel like I'm soooo close with this but still a no go.
With regen
http://www.youtube.com/watch?v=EEJZXapDXDU

When I hook it up on the trike it makes a little popping sound like it's missing. I have a couple of combinations that work good on the bench but not under load.
Wheels up
http://www.youtube.com/watch?v=VP4RykMsezM
Wheels down
http://www.youtube.com/watch?v=8BWOCszStMc

Under full load it has no power. :(

When I check the hall sensors they each cycle up and down and show 4.48 volts.
When I spin the tires manually and check the hall sensors I've never seen all three showing voltage at once so I'm pretty sure it's set properly at 120 degrees.
Power wire is 4.89 volts.
Phase wires start out at 1.7 volts or so and each cycle up and down with power. I've had it up to 6 volts and the wheels spin faster than I want to chance it while having it up off the ground with no load.
I'm using all the software defaults on the controller. I did try regen and on my last test I disabled the auto temperature shutdown sensor for the motor (since I didn't have it hooked up).
http://www.newkellycontroller.com/KBLHelp.php

Resolution:
I feel like I'm soooo close with this but still a no go.

electric_motorc...
electric_motorcycle_china's picture
Offline
Last seen: 9 years 9 months ago
Joined: Wednesday, May 12, 2010 - 08:52
Points: 48
Re: Brushless motor doesn't run under load

it is so expeisive,,, competive with china motor .... almost 5-10times price

marylandbob
Offline
Last seen: 1 year 11 months ago
Joined: Monday, June 22, 2009 - 12:24
Points: 524
Re: Brushless motor doesn't run under load

WHAT were you using to power the controll/motor? To operate under load, a big battery or very high amperage power supply, of sufficient voltage is required. Something that can sustain 36 or more volts, and simultaneously provide 200 amperes or more! (Over 7,000 watts power)--Bob Curry

Robert M. Curry

br549
Offline
Last seen: 10 years 2 months ago
Joined: Sunday, January 24, 2010 - 15:03
Points: 4
Re: Brushless motor doesn't run under load

WHAT were you using to power the controll/motor? To operate under load, a big battery or very high amperage power supply, of sufficient voltage is required. Something that can sustain 36 or more volts, and simultaneously provide 200 amperes or more! (Over 7,000 watts power)--Bob Curry

It ended up that the sprocket was too big. Got a smaller sprocket and it works great!

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