DIY 0-5k throttle

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agniusm   10 MW

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DIY 0-5k throttle

Post by agniusm » Jun 18 2019 8:21am

Anyone done or seen diy 5k throttle? Looking to make one and need reference. Pots are cheap, throttles are not so i thought why not build one. I need it for lawn mower ehich has cable throttle.
I do have 3d printers so its easy to make something.
Which pot do i need? I bought linear motion 10K pot with 45mm of travel. My cable moves 24.5mm so it should cover my range. Any ideas?

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stan.distortion   10 W

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Re: DIY 0-5k throttle

Post by stan.distortion » Jun 18 2019 8:36am

Imo you'd be better avoiding pots, they'll last for a while but at some point they'll inevitably ware out. Throttle position sensors used to be a nightmare on cars, always giving trouble when they where resistance based. These days they're almost always done with hall sensors.

They're no more expensive than pots, often cheaper but don't usually give 0V to input voltage as their output, usually something more like 1-3.5v for a 5v supply but all that's needed is a sensor and a moving magnet. Any kind of movement that effects the field strength or direction, rotating so the field varies between in line with the sensor and at some angle under 90 degrees to the sensor is fine (or over 90, some vary their output in both directions), as is moving the magnet towards and away from the sensor.

A few of examples:
https://www.simpits.org/geneb/?p=299
http://simhq.com/forum/ubbthreads.php/u ... ype/thread
https://www.electronics-tutorials.ws/el ... ffect.html

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DanGT86   10 kW

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Re: DIY 0-5k throttle

Post by DanGT86 » Jun 18 2019 9:15am

I thought the same thing about throttle position sensors being hall sensors until someone corrected me on a forum. Apparently they are mostly pots and reliable for millions of cycles. They also aren't as vulnerable to EMF. I would look at an automotive TPS for cost and waterproofing. I'd grab one from a salvage yard possibly with the whole throttle body its mounted to. You could use the original throttle body to reverse engineer the linkage and return spring pretty easily or just cut the needed parts off and mount them to your machine.

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stan.distortion   10 W

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Re: DIY 0-5k throttle

Post by stan.distortion » Jun 18 2019 9:48am

That would make sense, I'd stripped a couple recently and they where both hall and I'd assumed it was now the industry standard but I'm also having a sensor issue on an EFI system (megasquirt). Took ages to track down, no engine position signal while cranking, turns out the cause is noise from an almost worn out starter motor, ie. EMF. Good point on using the whole throttle body, throttle cable linkage and everything in one handy (and durable) unit.

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spinningmagnets   100 GW

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Re: DIY 0-5k throttle

Post by spinningmagnets » Jun 18 2019 10:35am

Fechter published a circuit a few years ago

"Throttle Smoother 3.0 - Linear Ramp Circuit"
viewtopic.php?t=47843#p708583

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MJSfoto1956   10 kW

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Re: DIY 0-5k throttle

Post by MJSfoto1956 » Jun 18 2019 3:56pm

I'm ditching the cheap, twitchy hall throttle that came with my Chinese electric scooter/moped in favor of a remote POT activate by a good-old, tried-and-true throttle cable. I've ordered one of these from AliExpress: https://www.aliexpress.com/item/Electri ... 09008.html. When it comes in, I'll report back.

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agniusm   10 MW

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Re: DIY 0-5k throttle

Post by agniusm » Jun 18 2019 4:21pm

Ok, will ditch pot throttle. Just found out that my controller has hall throttle support. Its industrial navitas tpm400

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agniusm   10 MW

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Re: DIY 0-5k throttle

Post by agniusm » Jun 18 2019 4:29pm

MJSfoto1956 wrote:
Jun 18 2019 3:56pm
I'm ditching the cheap, twitchy hall throttle that came with my Chinese electric scooter/moped in favor of a remote POT activate by a good-old, tried-and-true throttle cable. I've ordered one of these from AliExpress: https://www.aliexpress.com/item/Electri ... 09008.html. When it comes in, I'll report back.

Image

M
Thanks for the link, ordered. It does not say but is it pot or hall? Either way this fits me good. Thanks for the link

dustNbone   10 kW

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Re: DIY 0-5k throttle

Post by dustNbone » Jun 18 2019 8:45pm

I see 3 wires so I'm thinking hall sensor.

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MJSfoto1956   10 kW

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Re: DIY 0-5k throttle

Post by MJSfoto1956 » Jun 18 2019 8:57pm

dustNbone wrote:
Jun 18 2019 8:45pm
I see 3 wires so I'm thinking hall sensor.
AFAIK, most POTs use 3 wires too (see photo below). Notwithstanding, if it doesn't provide better behavior than my current cheap, twitchy Chinese Hall throttle, I'll simply hack it to use a high-quality POT instead. Something like this:

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amberwolf   100 GW

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Re: DIY 0-5k throttle

Post by amberwolf » Jun 18 2019 11:41pm

If you need to use a cable-operated hand control to run a throttle, there are a number of "pot box" controls, for ATVs, motorcycles, cars, etc. Both hall and pot versions exist.

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agniusm   10 MW

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Re: DIY 0-5k throttle

Post by agniusm » Jun 19 2019 12:16am

amberwolf wrote:
Jun 18 2019 11:41pm
If you need to use a cable-operated hand control to run a throttle, there are a number of "pot box" controls, for ATVs, motorcycles, cars, etc. Both hall and pot versions exist.
Yes, but they are like 50$. I dont want to pay 50$ for a pot.

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agniusm   10 MW

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Re: DIY 0-5k throttle

Post by agniusm » Jul 03 2019 2:41pm

MJSfoto1956 wrote:
Jun 18 2019 3:56pm
I'm ditching the cheap, twitchy hall throttle that came with my Chinese electric scooter/moped in favor of a remote POT activate by a good-old, tried-and-true throttle cable. I've ordered one of these from AliExpress: https://www.aliexpress.com/item/Electri ... 09008.html. When it comes in, I'll report back.

Image

M
Got mine and mated to original lever. Pretty sweet. I think i got full throw. Its for lawn mower i'm converting.
Great find

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MJSfoto1956   10 kW

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Re: DIY 0-5k throttle

Post by MJSfoto1956 » Jul 03 2019 7:15pm

agniusm wrote:
Jul 03 2019 2:41pm
Got mine and mated to original lever. Pretty sweet. I think i got full throw. Its for lawn mower i'm converting.
Great find
Yeah, it seems pretty sweet and the price is right. So far the "feel" is exactly what I was looking for. In the next week I hope to be able to report as to whether or not the "twitchiness" is reduced or not.

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serious_sam   10 mW

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Re: DIY 0-5k throttle

Post by serious_sam » Jul 29 2019 5:16am

MJSfoto1956 wrote:
Jul 03 2019 7:15pm
Yeah, it seems pretty sweet and the price is right. So far the "feel" is exactly what I was looking for. In the next week I hope to be able to report as to whether or not the "twitchiness" is reduced or not.

M
Any update on the remote throttle pot?

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Re: DIY 0-5k throttle

Post by j bjork » Jul 30 2019 3:25pm

I think you can find something nice in a scrapyard for old cars. I know many old vw and audi tdi (diesel) cars had a pot for the accelerator pedal. It was before it was integrated in the pedal, when all cars had got "drive by wire". So look at cars from the mid 90s to early 2000s. There were probably similar solutions on other brands.
Or you could probably use a throttle pot mounted on the throttle from a gas car from the same period, before "drive by wire" when everything got integrated in the throttle body.

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MJSfoto1956   10 kW

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Re: DIY 0-5k throttle

Post by MJSfoto1956 » Jul 30 2019 8:08pm

serious_sam wrote:
Jul 29 2019 5:16am
Any update on the remote throttle pot?
The combination of this AliExpress throttle + new AE96600 controller is a dream: I can feather the throttle and ride the bike as slow as 1mph without any twitchiness. However, I cannot tell you what portion of this welcome behavior is due to the throttle and what portion is due to the controller. I'm just a happy camper.

M
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serious_sam   10 mW

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Re: DIY 0-5k throttle

Post by serious_sam » Jul 31 2019 4:51am

MJSfoto1956 wrote:
Jul 30 2019 8:08pm
serious_sam wrote:
Jul 29 2019 5:16am
Any update on the remote throttle pot?
The combination of this AliExpress throttle + new AE96600 controller is a dream: I can feather the throttle and ride the bike as slow as 1mph without any twitchiness. However, I cannot tell you what portion of this welcome behavior is due to the throttle and what portion is due to the controller. I'm just a happy camper.

M
Cool. Thanks for the update.

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Re: DIY 0-5k throttle

Post by Aeron » Jul 31 2019 6:52am

dustNbone wrote:
Jun 18 2019 8:45pm
I see 3 wires so I'm thinking hall sensor.
serious_sam wrote:
Jul 29 2019 5:16am
Any update on the remote throttle pot?
I have one on my build. It's definitely a hall (opened it to extend the wires).
Runs perfect with a NCY throttle.

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MJSfoto1956   10 kW

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Re: DIY 0-5k throttle

Post by MJSfoto1956 » Sep 20 2019 7:30pm

MJSfoto1956 wrote:
Jun 18 2019 3:56pm
I'm ditching the cheap, twitchy hall throttle that came with my Chinese electric scooter/moped in favor of a remote POT activate by a good-old, tried-and-true throttle cable. I've ordered one of these from AliExpress: https://www.aliexpress.com/item/Electri ... 09008.html. When it comes in, I'll report back.

Image

M
Well Chinese quality rears its ugly head once again. Today while doing errands, my cable throttle simply broke leaving me stranded. Photo below. I picked up a "naked" bicycle brake cable which I will need to customize to work with this unit. Needless to say, this has me concerned. As such, I am taking extra precautions regarding any stresses on the cable as well as ensure proper lubrication. Additionally, I'm updating the unit to work with the following bits from Amazon which should allow me to swap things out again much more easily than this first go around: https://www.amazon.com/gp/product/B000C ... le_o00_s00. I recommend having these items available in your kit as an insurance policy for anyone considering this throttle cable/electric throttle from AliExpress.

YMMV
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Re: DIY 0-5k throttle

Post by amberwolf » Sep 20 2019 10:51pm

If you want a good reliable smooth cable, Jagwire is worth it (get the housing *and* the cable from them).

They come in bicycle shifter or brake types, either in precut lengths for front or rear common bike sizes, or in "shop kits" that are uncut housing and cable, with end-fixing bits. .

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MJSfoto1956   10 kW

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Re: DIY 0-5k throttle

Post by MJSfoto1956 » Sep 24 2019 1:11pm

Anyone considering using the above-mentioned AliExpress throttle box should make the following modification as an insurance policy. The basic idea is to replace the proprietary double-ended cable that comes with the throttle box with a stock bicycle brake/shifter cable. Thread the closed end and attach inside your hand throttle leaving the "naked" part of the cable to attach to the square throttle body as shown in the photo below. You will need to carefully open up the hole to accept the slightly larger diameter 1/4" Dorman 3336 Cable Lock which I purchased from Amazon.

Now if my throttle breaks again, I can go to any bicycle shop in the country for an inexpensive replacement cable.

YMMV
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John in CR   100 GW

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Re: DIY 0-5k throttle

Post by John in CR » Sep 28 2019 2:47am

Use a 0-5V TPS. Those are hall type and pretty cheap for an essentially no way to fail automotive grade hall. How much was that cable put box above? I've only seen them for about $50 too, too rich for my blood.

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Re: DIY 0-5k throttle

Post by Amiran » Sep 28 2019 5:41am

Looked up TPS, they come variety of price and make.
Good thinking!

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MJSfoto1956   10 kW

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Re: DIY 0-5k throttle

Post by MJSfoto1956 » Sep 28 2019 9:08am

John in CR wrote:
Sep 28 2019 2:47am
...How much was that cable put box above? I've only seen them for about $50 too, too rich for my blood.
Huh? $7.50 including shipping via AliExpress. Here's the link to where I purchased it from: https://www.aliexpress.com/item/3295490 ... 4c4dsaEBhk
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