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New controller that is capable with the stock Bosch

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Bvzijverden
Posts: 31
Topic starter
(@bvzijverden)
Eminent Member
Joined: 4 years ago

Hi guys, 

After building a new battery with 350A peak output and having done a shunt mod on the stock controller, the TC now performs a million times better.
Top speed has increased to 81kph (only reachable with 100% SOC) and a much faster acceleration. 0-30kph is still meh / 30-60kph is pure joy / 60kph - 80kph is fine.

Even though some top speed and a better acceleration from standstill would be appreciated, I decided to keep the stock controller as the bike rode just fine until.... I started tripping the circuit breaker 😑 . I decided to bypass the breaker and let the controller use whatever it wanted to use. Unfortunately now at the moments that the breaker would've tripped, the bike would simply switch off and the BMS showed a error.. time to put the breaker back in it.

Long story short is that I want to get a new, more powerful controller since the stock motor can handle a lot more than just 3kW.
Hence my question for the community would be which aftermarket controllers are compatible with the stock motor. Changing the display is not a problem since my stock display doesn't not get a data signal anymore (no speed indication, speed mode info nor error code info).
This probably happened when I cut away the unused connector the bike comes from the factory and cut away a wire too many.. 😓 

Any info about the stock Bosch motor is appreciated or directly a suggestion into which controller will work :).

Happy holidays and stay safe. 

Bob 

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2 Replies
 Tib
(@tib)
Joined: 2 years ago

Active Member
Posts: 5
Posted by: @bvzijverden

Hi guys, 

After building a new battery with 350A peak output and having done a shunt mod on the stock controller, the TC now performs a million times better.
Top speed has increased to 81kph (only reachable with 100% SOC) and a much faster acceleration. 0-30kph is still meh / 30-60kph is pure joy / 60kph - 80kph is fine.

Even though some top speed and a better acceleration from standstill would be appreciated, I decided to keep the stock controller as the bike rode just fine until.... I started tripping the circuit breaker 😑 . I decided to bypass the breaker and let the controller use whatever it wanted to use. Unfortunately now at the moments that the breaker would've tripped, the bike would simply switch off and the BMS showed a error.. time to put the breaker back in it.

Long story short is that I want to get a new, more powerful controller since the stock motor can handle a lot more than just 3kW.
Hence my question for the community would be which aftermarket controllers are compatible with the stock motor. Changing the display is not a problem since my stock display doesn't not get a data signal anymore (no speed indication, speed mode info nor error code info).
This probably happened when I cut away the unused connector the bike comes from the factory and cut away a wire too many.. 😓 

Any info about the stock Bosch motor is appreciated or directly a suggestion into which controller will work :).

Happy holidays and stay safe. 

Bob 

Do you still have the stock controller? Can you send some photos of your shunt mod? I am interested on it.

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 Tib
(@tib)
Joined: 2 years ago

Active Member
Posts: 5

 

 

Is this the shunt you have enforced to get more current out of the controller?

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wagner
Posts: 51
(@wagner)
Trusted Member
Joined: 4 years ago

I am currently building a TC with VESC 75 300 .

It´s based on open source, so you could even build your own display.

300A cont. at 16S.

But for real, the stock motor can´t handle more than 3kW continuous..
I pushed 4 kW peak into it and the motor got pretty hot after just 5-6 0 to top speed accelerations.
That´s why I placed a qs205 into the Soco with hubsink cooling plates..hopefully that´ll do it 😀

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Bvzijverden
Posts: 31
Topic starter
(@bvzijverden)
Eminent Member
Joined: 4 years ago

Would it be possible to get the stock display working with this controller? 
If this is possible at all, I doubt I'd have the required skill but if you'd be able to figure it out, I'd happily pay you for it.. it'd make my life easier when I have to get the motor tested in 3 years time and thus it's worth paying a bit to keep the stock display.

Regarding the motor heating up;
With my current setup I'm pushing ~120A (roughly 7kW) peak without the motor ever getting warm in the slightest -not even after aggressive "stop and go" city driving for 30min. Strange that yours got warm after just 5 top speed accelerations.

Today I will conduct some proper tests to see what my current peak and continuous ratings are. 

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wagner
Posts: 51
(@wagner)
Trusted Member
Joined: 4 years ago

Yeah, the original display has RS485 connection, which the VESC supports.
So maybe you´d need to change the firmware of the latter in order to communicate with the original display but that is too complex for me as for now.. 😀
Fortunately, a guy from the Netherlands already did something like this, he decoded the display massages and manipulates them with a small µC.

I´ll use a Koso speedometer with CE certification for just 100€ which does the job too.
As for data of the inverter, I can use my phone to even switch profiles, adjust settings on the go, ...

Regarding motor:
Did you manipulate the maximum phase amps of your stock inverter too?
Because I used a kelly controller with 350A phase peak which heated up the motor incredibly fast 😀

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Bvzijverden
Posts: 31
Topic starter
(@bvzijverden)
Eminent Member
Joined: 4 years ago

Do you remember who it was exactly that achieved this conversion of the display? Or perhaps the topic title so I can do some hunting. 

Where did you get your VESC from, it's starting to sound like the most reliable option.
I was looking at the Kelly KLS7230S but since they're miles behind in the display department, that's a no go unfortunately. 

Didn't manipulate the max phase amps or at least not with me knowing about it 😆
All I did was add solder to the shunts and the PCB traces for the FETs. 
After 10min of continuous full power stop and go, the motor got slightly warm to the touch but nothing that alarmed me.
The max power was 123A @ 61,2v.
Upon closer inspection the current raises quite slowly which might be the reason that the temperatures are kept at bay.

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