Adding external Hall sensors

[tomaj]

Hi,

I have Heinzmann BLDC motor, PMS120, same as the one in Brammo Enertia.
So, this motor has digital encoder for logging shaft position. According to this, I have to use Sevcon Gen4 controllers, which are very expensive. Motor was 400€ and Gen4 is 1100€

I would try with Kelly or those Sabvocan controllers, but they only support hall sensors.

Can I just mount external hall sensors on shaft, perhaps on sprocket?
Do you suggest any better solution?

 

[DGonz]

I'm using a Sevcon Gen 4 size 4 for my Electric motorcycle. It's expensive, but SOOO worth it.

Try calling up either Heinzmann or Kelly. For Kelly it may be a matter of adjusting the firmware to a custom one, or trying an experimental one. For Heinzmann, they may be able to send you a hall sensor adapter. All of the above are cheaper than buying a Sevcon.

Additionally, you can try making your own hall sensor board/adapter. My friend has some for sale that he designed himself for mid-sized hobby BLDC motors: http://e0designs.com/products/hall-effect-sensor-board/
You may be able to contact him and ask for advice on designing your own custom-sized hall sensor rig, though I think your best bet it calling Heinzmann up and buying a replacement sensor board designed for that motor.

I have a blog post on replacing the hall sensors on a Brushless Etek motor here: http://yameb.blogspot.com/2013/07/replacing-brushless-etekmarsmotenergy.html
I just called up Motenergy and they sent me a replacement hall sensor board free of charge. Then it was a matter of taking the thing apart without breaking it or me. (Those magnets are huge and powerful)

Good luck!