Help Needed: Signal Inversion for E-Bike Brake Light System Using 60V Brake Levers

mhrashof

1 µW
Joined
Jun 26, 2024
Messages
4
Location
Europe
I'm working on an e-bike project and ran into problem with my brake light system. I need some advice on how to invert a signal for my brake light setup.
The brake light should turn on when the brake levers are pressed, but the problem is that the brake levers are designed to cut off power to the motor when activated. So it goes like this:
Brake Levers: When not pressed, they output 60V. When pressed, the voltage drops to 0V. Brake Light: It needs a power signal to turn on. However, the brake levers provide power when not pressed and no power when pressed, which is the opposite of what I need.
What I Need: A device or method that inverts the signal from the brake levers so that when they are not pressed (60V), the output is 0V, and when they are pressed (0V), the output is 12V to power the brake light.
Solutions Considered:
Mechanical Relays:

SPDT relays could be used to invert the signal, but I'm concerned about their longevity and the mechanical wear over time. I need a more reliable solution that doesn't rely on moving parts.
Solid-State Relays (SSRs):
A more durable option, but I'm having trouble finding SSRs that match the specific voltage requirements (60V input to control 12V output).
Transistor-Based Inverter:
Using an NPN transistor with diodes to create an inverter circuit. This approach would be more reliable and have no moving parts.
However, I'm unsure about the exact wiring and component values to use.
Desired Outcome:
A reliable, durable solution that inverts the brake lever signal to properly control the brake light.
Ideally, a solid-state solution or a simple electronic circuit that can handle the voltage levels involved.
Any Advice? Has anyone dealt with a similar situation or have suggestions for components or circuit designs that could work here? Any advice or pointers would be greatly appreciated!
Thanks in advance for your help!
 
Great post.

I think you’ve covered all bases.

I’d probably use a relay, because I have dozens of them gathering dust, and take satisfaction in repurposing parts leftover from other projects.

I give them more credit for reliability than you do it seems.

It needn’t be a single pole relay - you can bridge multiple poles for increased current handling.

Needn’t be a 60V coil either.

I know you’re concerned about robustness, but surely a couple of 24V coil 30A automotive relays in series would be amply indestructible? For $5 each it might be worth finding out. 30V is just within spec for nominal 24V coils.
 
Back
Top