Matching Motor's Phase leads and Hall Sensors

[just]

Hi All,

I'm about matching the Phase and Hall Sensor leads.

I've actually found 3 combinations between the Phase leads and Hall Sensors, which according to all the rules (motors runs smoothly without noise and consumes less than 2A without load) should be the correct combination. How it might be?

Here are the combinations:

Combination#1:
Power Leads: | Hall Sensors
Motor <-> Controller | Motor <-> Controller
--------------------------------------------------------
yellow <-> yellow | yellow <- blue
green <-> blue | green <- yellow
blue <-> green | blue <- green

Combination#2:
Power Leads: | Hall Sensors:
Motor <-> Controller | Motor <-> Controller
--------------------------------------------------------------
yellow <-> blue | yellow <-> green
green <-> green | green <-> blue
blue <-> yellow | blue <-> yellow

Combination#3:
Power Leads: | Hall Sensors:
Motor <-> Controller | Motor <-> Controller
--------------------------------------------------------------
yellow <-> green | yellow <-> yellow
green <-> yellow | green <-> green
blue <-> blue | blue <-> blue

Thank you!

 

[zener]

What motor and what controller you have ?

Normaly there is only 1 combination where it runs under load in right direction smoothly.

 

[just]

What motor and what controller you have ?

Normaly there is only 1 combination where it runs under load in right direction smoothly.

I know, but for me all 3 above work... Same performance, same current consumption... I cannot explain why...

 

[fechter]

Actually, that is correct. There should be 3 combinations out of the 36 that work. From a good configuration, if you advance the hall and phase wires in the same direction, the phase-to-hall timing will stay the same.

 

[just]

What motor and what controller you have ?

Motor: geared 48V 350W hub motor
Controller: Kelly KBS48051EL

 

[just]

Actually, that is correct. There should be 3 combinations out of the 36 that work. From a good configuration, if you advance the hall and phase wires in the same direction, the phase-to-hall timing will stay the same.

Hm... That's what actually happens... But in all forums and also in the user guide of the controller appears that there should be only a single true match between the Power Leads and Hall Sensor signals, all others are false matches...
So, do you say what a number of matches might be 1 or 3 depending on how the Motor was wired? Good to know!
BTW, could you please take a look on the configurations, which worked for me - you could see them in the my first post in the thread? Do they make a sense? After finding the first combination, is it possible to know what are two another ones?
Thank you!

 

[NeilP]

What motor and what controller you have ?

Normaly there is only 1 combination where it runs under load in right direction smoothly.

As fechter said, 3 combos is correct. for the reason he mentioned.

It is possible with some more esoteric motors and controllers that there is only one combo that will work, but for most, if not all the generic kit DD motors and controllers , yes you will have 3 working combos.

After finding the first combination, is it possible to know what are two another ones?
Thank you!

IN theory, yes,
The order of the colours is always the same.
Note how you have written the Power leads, always in the same order
Yellow
Green
Blue

now look at the corresponding controller colours.

the order is always the same ..blue green, yellow. it is a 'rotation' ...so blue fires, green fires, yellow fires, then back to blue again and the cycle repeats as the wheel rotates.

Note all your working combinations ..it is always that same pattern..only the starting colour changes
Sequence no.1 starts yellow
Sequence no.2 starts Blue
Sequence no.3 starts green

when looking at the controller wire order..keeping the motor order the same.

SO in the way you have written it..your power phase lead order is blue green yellow

now look at the hall wires..that order is Green Blue yellow...and each working combo, keeps that same order.



in these direct drive motors..(not geared) there will be 6 smooth working combos...3 forward, 3 reverse.

So if you find a working combo, in the WRONG direction...just swap ONLY two pairs of phase wires and two pairs of halls

Not quite as simple, though, because just swapping any two pairs of both halls and phases, will probably result in the halls set for one combo and the phase set for another..so once you have swapped the pairs of both phase and hall, then you just need to keep one set unchanging (eg leave the halls) and then try the three different ' start colours' . for the phase wires..keeping the order the same..

So again in your case Combo number one...your forward colour order is yellow, blue green...so a smooth reverse will be yellow, green, blue

 

[alsmith]

Another 'that's right' from me.

Some people claim one works better than others but I personally doubt it unless the motor windings or magnets aren'tt positioned properly during manufacture but even then I doubt anything would be noticeable.

 

[NeilP]

I just noticed you have geared motor.

So obviously my comments about it running backwards with some combos , it won't spin the wheel backwards, but the motor inside may well run backwards. Never tried