Introduction
Welcome to the world of E-Rickshaw controllers, a critical component driving the efficiency and reliability of modern electric three-wheelers. These controllers serve as the heart of your vehicle, expertly managing the power distribution to ensure a smooth and safe ride. Whether you’re maneuvering a tuk-tuk truck through bustling city streets, operating an e-rickshaw van for passenger transport, or handling an electric loading auto for goods carriage, the controller plays a pivotal role in your vehicle’s performance.
This guide, meticulously crafted by AGL-Trike, a leading manufacturer in the three-wheeler industry, is designed to empower you with essential troubleshooting knowledge. Our goal is to equip you with the know-how to diagnose and resolve common issues, ensuring that your electric three-wheeler continues to operate at its best. With this comprehensive guide, you’ll be able to understand the basic functions of E-Rickshaw controllers and confidently take the next steps in maintaining the heart of your electric vehicle.
Controller Maintenance Methods for Electric Three-Wheelers
Measuring Without Wiring
Before connecting anything to the controller of your e-rickshaw van, use a multimeter set to 200K ohms to measure the resistance between the three-phase wires. A reading above 18K ohms is normal and indicates that the controller is likely in good condition. However, if the resistance is below 18K ohms, this could signify a burnt-out power tube, a typical issue that needs attention to ensure the smooth operation of your vehicle.
Visual Inspection
Before activating the controller in your electric three-wheeler, such as a tuk-tuk scooter, it’s crucial to perform a careful visual inspection. This step is particularly important in vehicles with complex electrical systems like 3-wheel electric trucks. Ensure that each plug is correctly connected, checking the wire colors for accuracy. This simple yet effective procedure can prevent misconnections that might lead to potential controller damage, thereby maintaining the efficiency and safety of your vehicle.
Testing with a Multimeter After Powering the Vehicle
Testing with a Multimeter After Powering the Vehicle
- Issue: The motor does not turn when the throttle is rotated.
- a) Voltage Check: Use a multimeter set to the DC 200V range to measure the voltage across the power line and the ignition lock line. For example,if your Passenger Electric Tricycle motor voltage is 60V, You should see a reading of 60V. If there’s no 60V, inspect the power cables for proper connection.
- b) Brake Circuit Inspection: Check if your bajaj tuk is in a braking state (tail light on during braking). Use a multimeter to monitor changes in the brake signal level.
- c) Motor Hall Sensor Check: Assess the functionality of the motor hall sensors, following specific testing methods(Please see next paragraph).
- d) Throttle Power Supply Measurement: On the DC 20V setting, measure the voltage between the throttle’s red and black wires. A reading of about 4.3V is expected. If not, this might indicate an internal power source issue in the controller.
- e) Throttle Signal Line Measurement: Continue using the DC 20V setting to measure the voltage of the throttle signal line (green) against the ground (black). During throttle rotation, the voltage should change linearly between 0.8V and 4.2V. If constant, consider replacing the throttle or the controller.
- Issue: Bajaj 3 Wheeler stuck in low speed, unable to switch to high speed
- Low-Speed Lock Inspection: Examine the low-speed lock wire (grey and black) for a short circuit. Disconnecting this may allow the vehicle to switch speeds.
- Battery Voltage Under Load: Measure the battery voltage under load using a DC 20V multimeter setting. If the voltage is below the undervoltage value, it might prevent speed switching. This occurs to protect the battery. Retest with a fully charged battery for accurate assessment.
Motor Hall Sensor Repair Methods for Electric Three-Wheelers
A. Visual Inspection
Begin by visually inspecting each connector in your electric three-wheeler, which could be a passenger carrier or a utility vehicle. Ensure that the wire colors of each plug are correctly matched and that the connector pins and springs are properly engaged. This step is crucial in preventing misconnections or poor contact, which can lead to malfunctioning of the motor in vehicles like rickshaw vehicles or electric cargo trikes.
B. Hall Sensor Testing Methods
- Using a Multimeter:a) Hall Power Source Measurement: Set your multimeter to the DC 20V range and measure the voltage between the red and black wires of the Hall sensor. A normal reading should be around 4.3V. This step is vital for vehicles like e-rickshaw vans, where precise motor control is essential.b) Observing Hall Signal Line Voltage: Still on the DC 20V setting, observe the working voltage of each Hall signal wire (yellow, green, blue) against the ground. Slowly rotate the motor and watch the voltage change on these wires. In a typical electric powered trike, the voltage should vary between 0V and 4.3V. If one phase does not change, it indicates a fault in that particular Hall sensor.
- Using a Hall Tester: Connect the Hall tester to the motor of your three-wheeler, which could be a model like a bajaj 3 wheeler. Power up and slowly rotate the motor. Observe if the LEDs corresponding to each signal line blink. If any phase does not show variation, it suggests a malfunction in that Hall sensor.
Conclusion
This guide crafted by AGL-Trike, experts in electric three-wheeler production, has been designed to offer you a thorough understanding of the maintenance and troubleshooting processes for your vehicle. We’ve delved into the intricacies of controller care and provided in-depth instructions for inspecting and fixing motor hall sensors. Our aim is to help you keep your electric three-wheeler, whether it’s for passenger transport or cargo, running smoothly and dependably.
If you encounter any issues or require further assistance, remember that AGL-Trike is just a contact away. Our expertise in the field of electric tricycle, including rickshaws and utility vehicles, ensures you have support whenever needed.
Additionally, for those interested in delving deeper into motor malfunction resolutions, we recommend exploring our detailed guide on electric motor troubleshooting. This resource is designed to provide you with an even broader understanding of managing and resolving motor-related issues in your electric three-wheeler.
