KEB Kelly Controller, Motor/Wheel locks up

[TAz00]

Hi,

Mind the noobness, first post.
It's hard to find help in this, so I thought I would come here.

I've been building my second EV for some time, and I've finally got it running.

It's your standard 130kv turnigy with external hall sensors, and a KEB 3kw (no regen) controller. Powered by 4x6s 5000mAh LiPo's.
Bored out the 5mm thread on the motor to 8mm, and inserted an M8 threaded pinion. Also replaced the bearings.

My problem is the wheel/motor locks after releasing throttle, and throttling up while rolling. Like it's setting the RPM to 0 and then ramping up. There are no error codes to be seen.
Video @ 0:24 the rear wheel blocks: https://www.dropbox.com/s/cjyuqlo04yanq24/2014-07-09 11.01.09.mp4

Makes for a quite unerving ride.

Anyone have any advice?

Best Regards

 

[Drunkskunk]

Welcome to the forum. Looks like a fun build.
I can't see that video, as Norton pops a Trojan warning on it.

Its hard to tell from the pic, but at a wild guess, I'd say you're running a sensorless motor directly geared to the rear wheel, with no freewheel? yeah, thats going to lock up sometimes when you get on the throttle. The controller has to figure out which way to spin the motor. if it's already spinning, the controller may get it wrong, try to spin it backwards, and lock it up hard. It happens to RC planes, too. Cut the throttle in a dive, then try to put on power at the end of the dive. But the motor is spun up from the air blowing past it, and locks up hard for a moment.
\
The cure may be either a freewheel, or adding hall sensors to the motor.

 

[riba2233]

He has external sensors, you should read more carefully

And besides, kelly doesn't have sensorless controller suitable for vehicles.

I would guess that there is a problem with external halls.

 

[Hugechainring]

You could try checking the output from the Hall sensor on the throttle with a voltmeter to see if it is operating properly to begin with. Then maybe run the configuration software for the controller again, and double check all the settings. One item I would look at is the throttle setup and calibration. It sounds almost like the voltage limits are out of whack, and the throttle is sending out an out of range signal at low throttle regardless of motor speed

Another item to look at is the speed vs torque mode setting. You may want to try torque mode or balanced mode with that setup, since it is so light and has a lot of power.

You may also want to try detuning the controller to get it stable,and then ramp the settings up slowly. I'm not familiar with that particular software, but I would try turning the phase and battery currents down, double check the LVC, and see what happens.

Is that a 12S 2P or a 6S4P? Which model KEB is that? 24-48V?

 

[TAz00]

Hi thanks for your replies.

I've been mailing with Kelly aswell, they're very helpful and suggested I disable ABS and Smooth settings, which I've done.

You can see it here https://www.dropbox.com/s/3xz9nhmxn1nzcdf/2014-07-12 08.50.00.mp4 (not sure why norton flags the video, it's straight from my phone to dropbox)
Now I forgot to show the LEDS (i know the red one works ) but they're all green, also while running.

It's both audible and visible that the controller breaks the free rotation of the wheel.

The controller is a KEB48300X 200A 48v 3kw model, with 12S 2P batteries. Range low/high set to 45V - 50,4V.
I will have a go at programming balanced and fiddle with current settings today or tomorrow.

I've replaced the throttle from a 0-5V to a hallsensor throttle, it now has very smooth translation. I see what you're saying though, I will have a go at measuring the voltages.
Kelly also suggested I check voltage between J2 pin7 and J2 pin14.
I had 5 volts hooked up the the hall sensors and confirmed that they all toggle states.

Best Regards

Ps. the bike is an X2 I think, anyone know where I could get a freewheel which fits?

 

[riba2233]

lvc voltage is too high