How to connect a brushless motor to a controller?

General Discussion about large electric scooters and motorcycles and other things with no pedals.
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VRMinde   1 µW

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How to connect a brushless motor to a controller?

Post by VRMinde » Jan 13 2021 8:35am

I am installing the Kugoo Kirin S1 RWD wheel on my Xiaomi M365 scooter. I want the new wheel to run on a stock controller. Both wheels have the same amount of hall sensors - 3.
Image

How should I connect the wires correctly? My guess was that the hall sensor position is critical, therefore it should be like:
M365 - Kugoo
Yellow - Green (A)
B- - B- (-)
Blue - Yellow (B)
R+ - R+ (+)
Green - Blue (C)

But how do I know how to connect phase wires? Thank you for your help.
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amberwolf   100 GW

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Re: How to connect a brushless motor to a controller?

Post by amberwolf » Jan 13 2021 7:06pm

There is no way to know for sure which combination will work without testing them to find the lowest-no-load-current that spins it the right direction at the right speed.

You can *try* making sure the wire orders are the same, by matching the order of teh halls as tehy are on the boards you picture, *and* the phase wire orders as they are on the stator windings, but if the motors are wound in a different pattern from each other, that might not work.

If you do try it, then leave the motor wheel offground, and measure the battery current while slowly increasing throttle from zero to full. It should stay around 1A, maybe up to 2A, or less. If it is higher than that, especially significantly higher, or spins way faster than normal, then it's the wrong combo, and you'll need to explore other combinations of either hall or phase wires.

If it is in the wrong direction, then swap any two phase wires, and then experiment with hall wire combinations until you get the low current one that spins right.


Just curious--why change the motor? Did the original fail?

VRMinde   1 µW

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Re: How to connect a brushless motor to a controller?

Post by VRMinde » Jan 14 2021 2:55am

Thanks for the reply, I will be experimenting today and hope not to burn anything.

I am not exactly changing the motor - I am adding the second one :)

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amberwolf   100 GW

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Re: How to connect a brushless motor to a controller?

Post by amberwolf » Jan 14 2021 2:08pm

VRMinde wrote:
Jan 14 2021 2:55am
I am not exactly changing the motor - I am adding the second one :)
Well, if you don't already have one, you'll need a second controller to go with the second motor, so the easiest way to do that is to get a kit with both motor and controller in it that are matched for each other, so you can just plug in and go.

If you're already using a second controller identical to the original, then you should be set, once you determine the right wiring combination between it and the new motor. :)

As long as you use just a little bit of throttle, wheel off-ground, to do the testing, you shouldn't burn anything.

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TommyCat   1 kW

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Re: How to connect a brushless motor to a controller?

Post by TommyCat » Jan 14 2021 2:14pm

This may help...


Image
See my completed Magic Pie V5 rear hub E-Bike build Here!

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