Tag Archives: electric-bike-kit - Page 3

How-to-build-a-freewheel-hub-motor-for-electric-bike-conversion-kit

Posted by on May 31, 2020 Comments Off on How-to-build-a-freewheel-hub-motor-for-electric-bike-conversion-kit

These days 250w hub motor wheels are popular with European. Nearly all of hub bike motor are brushless geared. Because there are several gears inside hub. It has more powerful than 250w brushless geared motor.
Order 1 set 12″ 14″ 16″ 18″ 20″ 24″ 26″ 700c 27.5(650) 27″ 28″ 29 inch hub motor electric bike conversion kit , convert your common bike to e-bike is so easy. Directly front or rear drive your bike.
The important part is an engine -hub motor. How to build this? There are some differences with brushless freewheel hub motor.

Step 1: winding
Calculate motor power, speed RPM and confirm what type of copper wire would you use, wind copper wires by handwork or machine, each notch should be separated by insulating paper so that not shot circuit between the coil. It takes about 1 hour to done it by handwork. And should use rubberized fabric to wrap your fingers. Nipping copper wires will break your fingers.

Step 2: fix axis into motor
Put axis into rotor winding and use a key to fix axis. Use A-B glue to paste three hall sensors on hub motor rotor, put 9-pin (three pin/each hall) into PCB and use insulated wire to fix it. Put 8-pin cable inside the axis and heavy yellow, blue, green wires to connect the three copper wires(Phase A,B,C) separately. Thin red, black wires are be weld to PCB + and – .

Step 3:soak paint
After winding should soak paint in order to be insulated. Use brush to put the insulated paint on the winding and make sure be soaked everywhere. It takes about 24 hours.

Step 4:press gear into hub
Use presser to press steel 90-gear into hub. This hub with one side cover.

Step 5:fix three gears
Use retainer ring and key to fix three white nylon gears on one steel 21-gear.

Step 6:fix magnet
Fix magnet inside the hoops.

Step 7:install rotor winding into this magnet hoops.

Step 8:install there gears on the axis of this rotor winding and put inside of hub with 90-gears.

Step 9:install the other cover.
Use screw driver to tight screw nuts. Done it.

Power on battery and use bldc motor controller to drive this hub motor. If no any strange noise. It’s okay.Then according as the size of your bike to fit this geared spoke hub motor to 20″ 24″ 26″ 27.5″ 700c 27″ 28″ and 29 inch bike kit wheel.

Hub motor, bike kit, bike motor supplier: Leaf Motor Technology Co., Ltd

E-bike with electric bike kit almost done, but..

Posted by on May 25, 2020 Comments Off on E-bike with electric bike kit almost done, but..

E-bike with electric bike kit almost done, please help with final issue: Throttle

Q:I am almost done with electric bike kit, everything is ok except the throttle is not working. I connected the old throttle from my old e-bike, it’s connections fits the lcc-001 controller.But as I connect it, the motor doesn’t run at all.
What kind of throttle is to be connected to this controller to achieve speed control from 0 to full speed: potentiometer type or Hall Effect type?
My current throttle is 3 wired connected to a very small chip, which is moving along a magnet.

Answer 1:Pls check three-pin throttle connector.

Answer 2:Disconnect and re-connect these two connectors.Check male-female connector and pins.
If still not work,buy a new throttle or use a potentiometer to replace.

Answer 3:Make your electric bike kit wheel in the air,short red and green wires(3-pin throttle connector on controller).
Power on battery,motor will run as the fastest speed at once.
If not,it’s not throttle issue.

Answer 4:Yeah,jump red and green wires.If your system is no problem,e-bike can run at once.
Make sure your electric bike kit wheel in the air.

Answer 5:You had better to cut off three-pin throttle connector.Then connect wires as below:
Throttle —– Controller
red —– red
black —– black
white —– green

If you have volt-meter,pls power on,then test voltage from controller throttle connector.
1.red and black is about 4.5V
2.green and black is about 2.3V

Make a jumper between red and green,the electric bike kit wheel will run at once.

Done following above,if no any voltage and still no work.Pls replace controller.

Q:Thanks all,I dis-connected throttle connector and found green and white wires didn’t touch well.Re-made a new throttle connector,supply power,electric bike works without any noise.Prefer leafmotor’s electric bike kit.

issue about electric bike kit battery

Posted by on May 25, 2020 Comments Off on issue about electric bike kit battery

We purchased an electric bike kit including motor controller, hub motor wheel, throttle, brake lever and with 36V 10AH bottle style Lithium Ion electric bike battery that used for testing 36V solar charger from one supplier, not from leaf motor. After charging this electric bike battery for 10 hours by better solar power, full charged, we rode the bike, but hub motor wheel only run about 8km.

We use a ampere meter in series to electric bike kit system, powered on and rode it. We got the current is about 5A. The speed is 257RPM.We use 26” hub motor wheel.

We calculate the speed is about 32Km/per hour.
See below formula:
（3.14×26”×0.0254）× 257RPM × 60 minutes ÷ 1000 (m-Km)=32km

If this is 10Ah battery, per hour lost 8ah.We can use 1.25 hours.
See below formula:
10Ah ÷ 8ah/per hour= 1.25hours

We think full charge this electric bike battery per time, the hub motor wheel can run about max 40 km. 32km/per hour × 1.25 hours = 40 km

There is definitely a problem with this electric bike battery, I’m not sure whether electric bike kit is because of the solar charging or our testing, or if it has a fault. But I need a replacement electric bike battery asap, because we don’t have any more 36v electric bike battery, and we sold 1 set of electric bike kit with lithium battery last week. I think BMS inside this electric bike battery no problem. The problem comes from the li battery cells. Maybe this electric bike battery had stayed in warehouse for a long time and haven’t charged it. It will make the electric bike battery cut down the achieve distances and use life.

So if solve this problem and let my hub motor to work asap, only replace all cells or replace new electric bike battery.

Some issues about front hub motor electric bike kit system

Posted by on May 22, 2020 Comments Off on Some issues about front hub motor electric bike kit system

DIY 1 set of 26″ 36V 750W front hub motor electric bike kit from Internet shop,waited for a couple days,at last received it.
Checked packing box,it’s okay.Disconnected package,there were all goods inside box:

1.1 set of 26″ 36V 750W front hub motor wheel without tyre
2.1 set of 36V 750W bldc motor controller with LCD
3.1 set of twist throttle with battery gauge
4.1 set of brake lever with low voltage to brake
5.1 set of three-button switches(control horn,led lights,cruise..)
6.1 set of 36V 16Ah LiMn2O4 electric bike battery with 110~230AC charger
7.some zip ties(fix wires)
8.1 set of instruction manual and wiring diagram

Was told to prepare below tools to install electric bike kit:
1.open-end wrench(loose/tight screw nuts)
2.philips screwdriver(fix LCD)

By now,install electric bike kit seems very easy.But for a newer,first time to install electric bike motor (hub motor) wheel and need to connect various unknown wires that is still a little difficult.
Leafmotor will share some install experience with every DIY bike kit rider.Some issues you will meet:
1.You are going to install hub motor wheel,you should find out the motor’s direction of rotation first.Please read install instruction manual;
2.Install tyre according as flower pattern of tyre;
3.Fix 26” front hub motor wheel on front fork.If your front fork is 100mm,no problem.After installed,sometime you will find the wheel isn’t in the middle of fork,now you should use some washers to adjust.If still can’t solve it,the problem come from spoke rim should re-fit this rim;
4.Fix bldc motor controller,LCD,electric bike battery and install throttle,brake lever,three-button switches.This step is easy;
5.Make the electric bike motor wheel in the air, power on li battery and test bike kit system.If it works normal.Please use zip ties to fix wires.If not,re-check wire connecting according as wiring diagram.

This fifth step is the most important.When you power on battery,you may meet below issues:
1.The electric bike kit system can’t work.When you turn throttle,nothing is happened.Now you should check battery power connector and three-pin throttle connector;
2.The electric bike kit system works as the fastest speed suddenly.The problem is the black ground wire from throttle isn’t connected well;
3.The hub motor shake,please check motor phase wires;
4.All leds light,but electric bike kit still can’t work.Check motor wires;
5.The electric bike kit works,but just wok less than 3 seconds,all lights on throttle are off.Loose throttle,be on and the bike kit system still works less than 3 seconds.This is battery issue,use volt-meter to measure it.Full charged 36V limno4 battery is 42V and dis-charged it is 34V.The volt of your new battery can’t less than 34V.If it’s under 34V,please return it to your supplier.
6.LCD doesn’t display speed.Solve: the sensor should be closed to the detector.

Hub motor,electric bike motor,electric bike kit supplier: Leaf Motor Technology Co.,Ltd

Hub motor was very sluggish

Posted by on May 21, 2020 Comments Off on Hub motor was very sluggish

Question:While trying to get the hub motor up and running here we have run in to some problems. After installing the hub motor wheel in the fork it was very sluggish to turn and took quite a bit of effort, not freewheeling at all. The first time we plugged the battery (fully charged 48V 12AH LiFePo4 at 52.9V) in to hub motor (without the throttle connected to the controller cable) the hub motor beeped three times. When we hooked up the controller cable black and yellow pin connectors to the corresponding ones on the throttle there was no response from the electric bike motor, but the battery level lights did light up. We tried both throttles sent with the same results.

As it was the weekend I went to the forum and looked there for assistance. I received some good feedback that the 3 beeps we heard were a signal that the throttle was not work which is what we found as soon as we hooked up the throttle. We have checked all the leads for correct amperage as per his instructions with positive results.

I am assuming that electric bike kit is bench tested before it leave there? The packaging was undamaged upon delivery and all seemed in good order upon receipt. If you could please advise us on what to do to get this resolved we would appreciate it as we want to get on with our trials here to be able to get out product to market by summer.

I have checked my throttle and hub motor controller wires against your PDF diagram and there seems to be some discrepancy? I wish my camera was working but I will describe my findings. Diagram Throttle Black 3 pin shows: Red? perhaps Orange?/White/Blue Our Throttle Black 3 pin has:
Orange/White/Black from core with black jump to yellow 2 pin Diagram Controller Black 3 pin has: Red? perhaps Orange?/black/Yellow Hub Motor Controller Black 3 pin has: Rust from Core with Red Jumper to PAS White three pin/White/Black from core with Black jumper to yellow 2 pin

I checked the 8 pin connector again and can’t see that it isn’t making good contact. No bent pins or obstructions.Electric Bike Motor still beeps three times upon connecting to full battery as described with and without full connections of cables.

Yes jumping the two holes as indicated does make the electric bike kit run. It seemed like at first that by moving the controller wire that the electric bike motor would stop and start as if there was a short right at the junction and we thought that might be the problem. We hooked up the cable but I still am not getting any response from either throttle when hooked up to the black two pin connector even if I move the cable at the junction and now using the jumper the short method that issues seems to have gone away?

We are trying hard to make this electric bike kit work here but I have to admit we are getting a bit frustrated. The throttle cable while hooked up shows 5.0 amps on the red wire and from .8 amps at rest and 3.8 amps on the white wire when at full throttle like it should? Without the black pin connector together there are 5.0 amps at the red wire and .1 amps at the white wire if that is any useful information.

Hub motor,electric bike motor,electric bike kit supplier: Leaf Motor Technology Co.,Ltd

Hub motor kit ceased to function

Posted by on May 21, 2020 Comments Off on Hub motor kit ceased to function

On February 8th we ordered your 26″ 48V 1000W front electric bike kit(1 set of 26” 48 1000W hub motor wheel with lcd bldc motor controller,twist throttle,brake levers,48V lithium battery) which was delivered to us on February 13th.Shipment is very fast.But the packing box is broken,we disconnect it and found the left brake lever was defective and I e-mailed you about getting a replacement set of levers. You told me that the parts would be sent. They never were received. I disconnected the lever plugs and have been using the bike for the past 1 month without them being hooked up.

Last week the bike ceased to function. I have 50+ volts going to the bldc motor controller connection but when I plug in the hub motor controller, the voltage drops to 1.8V and nothing happens. When I disconnect the hub motor connection, the voltage remains at 1.8V. As soon as I disconnect the battery, the electric bike battery shows full voltage of 50+ volts. The voltage indicator lights do not light up at all. So I have good voltage going to the controller but nothing works. I disassembled the controller to see if there was a broken connection or burned out part but can find nothing visibly wrong – when I connect a tester to the board the voltage shows 1.8 when should be 50 at the input connection. Something is wrong internally and I now need the hub motor controller to be replaced. I am relying on the electric bike kit to get to and from work so time is very important to me.

Please send me a new hub motor controller as soon as possible. Also send me the previously promised brake lever set replacement at the same time (as long as it does not slow down the shipment of the hub motor controller). I would also appreciate it.

Hub motor,bldc motor,electric bike kit supplier: Leaf Motor Technology Co.,Ltd

Problem with electric bike hub motor kit

Posted by on May 18, 2020 Comments Off on Problem with electric bike hub motor kit

Good day.I have bought from you 1 set of 48V 1000W rear electric bike kit that includes 48V 12Ah li battery,48v lcd brushless motor controller,twist throttle,brake levers with 26″ 1000w hub motor rear wheel.Received all things.The order number lf283218U578679K. Shipment was fast and packing box was not broken.

But since I had installed hub motor wheel,motor controller,throttle..everything, I had following problems: Twist throttle was sometimes hard to begin electric bike motor uphill, with even slightest elevation.Electric bike kit either stops unintentionally, while I begin to accelerate hub motor, or doesn’t start at all. Usually it takes several amperes to start throttling.Electric bike motor never gets hot, only a little bit warm.

Electric bike kit (regenerative) brakes almost didn’t work at all. It is possible to stop with them only from the lowest speed of 5km/h approximately. If the speed is more than this, brakes just let the hub motor to freewheel. I don’t know if they are converting electrical energy.

When I tried to use USB cable to see, if it is because of lcd hub motor controller settings, I couldn’t connect to it. Software starts, when I choose “Connect” nothing happens with the program itself, only the electric bike motor starts to beep constantly. “Get settings” didn’t load any, changing parameters and saving them seems to have no effect on the electric bike motor. Only “Disconnect” button worked, but somehow it says that “Get settings” is complete, and any changes in parameters reset to their initial state. After approximately 360km, “Cruise control” button stopped to work. I opened hub motor and checked electrical connection to the motor controller itself, the button itself and wires are functioning properly. But I have absolutely no voltage reading on the button’s wires.

Read article from blog and forum,I doubt the problem comes from electric bike battery.It as said,there is a BMS inside lithium battery.Some cells would be dead because of overcharge or over discharge.If dead,can’t charge lithium battery.Even if charge it,green led on charger will light at once.It looks like full charge,actually no any electrical energy inside battery.So when I ride my hub motor electric bike,the electric bike motor will stop in short time.

Please, help me to resolve those electric bike kit problems, especially, with “Cruise control” button.

Hub motor,electric bike motor,electric bike kit supplier: Leaf Motor Technology Co.,Ltd

make a 48V hub motor electric bike kit work at 36V

Posted by on May 18, 2020 Comments Off on make a 48V hub motor electric bike kit work at 36V

I have recently bought a DIY electric bike kit from you, where I have bought a 36V battery and a 48V hub motor & brushless motor controller. I thought that when I ordered from your online internet shop, you would check, that the electric bike kit system would work..

On the homepage you write, that I can force the 48V hub motor controller to work with lower voltages.Also, the 48V thumb hub motor controller does not work. The twist controller works.

I have called your office and found out, that the problem is, that the 48V hub motor controller cuts off the electric bike kit system to protect the li battery. And the only solution is to manually override the system, but that is not an ideal way to operate the e-bike.

I have now ordered a new hub motor controller and thumb throttle for 36V from your homepage. What I would like you to do, is to write on the package you send me, that the package you send me is a guarantee replacement.

I do not wish to discuss guarantee and other issues with you, it is much easier for me to order new parts, but I would like to avoid to have to pay customs and VAT again for the same things. Also it takes weeks before the goods get through customs.

I also have one more suggestion for improvement:Please put 2*2 nuts on the electric bike motor wheel to be able to secure them, because my front 48V 1000w electric bike motor wheel fell off while I was starting with the e-bike. (while driven by 36V, ½ power – where I pull the break lever, push the cruise control 5 times, and use the cruise control to operate the electric bike motor) Also it would be nice if you could specify how hard I should tighten the nuts on the electric bike motor wheel.

20Nm? 60Nm?, I would like to tighten them well, but I do not wish to brake the thread. My transaction ID of electric bike kit order is 3FA78294KK410865B

Hub motor,electric bike motor,electric bike kit supplier: Leaf Motor Technology Co.,Ltd

power on the electric bike hub motor was gone

Posted by on May 16, 2020 Comments Off on power on the electric bike hub motor was gone

Electric bike hub motor kit was gone, how to solve it?

Received my electric bike kit .Product list:
1.26″ 36V 250W front brushless geared hub motor wheel
2.36V 6-MOSFET brushless motor controller working with LCD(display speed,mileage,battery gauge..)
3.standard black twist throttle with battery gauge
4.brake lever with low voltage to brake
5.three button-ON/OFF switches that are used for control front&rear lights,cruise,horn…

Check rim whether in the middle of fork and the direction of hub motor runs.Then I have installed everything on my bicycle according as instruction manual and the electric bike kit worked fine.

I was running e-bike about 25km and then I stopped the electric bike motor . Charged the electric bike battery because I was staying there for some hours. Started on the way home and after some heavy hills (about 3 km)it was completely dead. The electric bike kit system was running like normal up to this, but suddenly all power on the electric bike motor wheel was gone.

Those three led lights on twist throttle for electric bike battery were still lit. I tried to turn e-bike off and on again, but same result. Today the electric bike kit is still dead.

Do you have any idea? Measured 0,1 Ohm between the electric bike motor(hub motor phase wire: yellow, green, blue).Infinity between hub motor cable and hub motor cover. So it does not look like it is burned. The electric bike motor controller has 41,8 Volt input.

Measure the hub motor hall sensor:
Red, black, yellow, blue, green wires.
1.The voltage between red and black is 4.5V;
2.The voltage between yellow and black is 4.2V or 0V,(When use hand to turn hub motor, the voltage will change from 0~4.5V~0~4.5V)
3.The voltage between blue and black is 0.2V; (When use hand to turn hub motor, the voltage could not change)
4.The voltage between green and black is 0.1V. (When use hand to turn hub motor, the voltage could not change)

From above test data, I doubt there were two hall sensor inside the electric bike motor that were broken.

Electric bike hub motor kit was gone, how to solve it?

Hub motor, electric bike motor, electric bike kit supplier: Leaf Motor Technology Co., Ltd

The issue about 250W hub motor electric bike kit

Posted by on May 16, 2020 Comments Off on The issue about 250W hub motor electric bike kit

Bought 1 set of electric bike kit from one supplier in China two months ago. Sent more than 10 emails, haven’t gotten any reply. I met below issue, hope solve it.

When I was riding my electric bike three weeks ago, the 250w mini front hub motor suddenly started to make a strange and strong noise. If I try to turn the twist throttle on when the e-bike doesn’t have any load, I keep the hub motor wheel in the air. The electric bike motor works fine and electric bike kit does not make any noise.

However, if I try riding my electric bike and turning the throttle on, the electric bike motor starts making a strong and continuous noise. I tried to riding my bike keeping the brakes continuously pressed and any noise appears so it seems to be some electric problem. It is very strange and I am so much worried.

I took off electric bike kit wheel and used screwdriver to disconnect six screw nuts, took apart hub motor cover and found there was a rotor-winding, two bearings, three sets of 42-gear, 1 set of 21-gear on the axis, 1 set of 81-gear on the hub. There wasn’t any impurity inside the hub motor. Re-install and test electric bike motor wheel, still have the same problem. Don’t know what’s the problem.

Contact my supplier many times and can’t get any reply. I looked for answers by google, yahoo and bike forums, still can’t find the correct answer. Yesterday I got a message from my US friend about there was a company, leaf motor can help me. So I sent an email to leaf motor.

Surprisingly just half an hour past, leafmotor replied me and asked me to check the bearings. How to check hub motor bearing? Take off two bearings from axis, and use little finger to hold inside of bearing, the other hand to turn bearing, faster, better. If you can hear some noise from bearing that can confirm the problem comes from electric bike motor ‘s bearing. At last, I found there was a bearing was broken. According as the bearing model, I bought two new ones in market and replaced them.

Test electric bike kit wheel in the air, no noise. Brake hub motor wheel, still no noise. Nice, Have solved it.

I should thank leaf motor that help me and I found fun through repairing electric bike motor. Now I decide to buy leaf ‘s electric bike kit if I have need and will recommend my friends to order leafmotor’s electric bike motor, bike kit…

Though I haven’t ordered any goods from leafmotor by now. But they are very professional, has best service and believe they have high quality products.

Hub motor, electric bike motor, electric bike kit supplier: Leaf Motor Technology Co.,Ltd