DIY electric bike: throttle

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Hello friends!

It’s amazing how much the throttle itself affects the mileage of an e-bike. After all, when she is not there, and you are forced to pedal, and the bike helps you, this is one thing. But it is completely different when it is at your fingertips, and when riding uphill, you are tempted to use it!

In fact, most Russian e-cyclists use the throttle stick.

Today I propose that you familiarize yourself with the types and structure of throttle grips for electric bicycles, and also consider their principle of operation.

Depending on whether

In addition, depending on the required

Accordingly, depending on the functionality, the number of wires that go from the throttle stick to the controller also changes.

If you look at the throttle grips, which are ordered most often on Aliexpress, it turns out that they are Full-twist (fully rotated).

The part from which the wire comes out is attached to the handlebars with a hexagon, and the rest of the rotates.

The only thing

Huge

In addition, if you just grab this handle when the e-bike is on, you can accidentally turn it and the bike will go. While mechanically trying to hold it, we will turn the knob even more. Such cases occur, and not infrequently.

The Half-twist throttle grip is safer, with only half of the throttle turning and the other half fixed to the handlebars. Thus, you can hold on to the stationary half, and throttle the rotating half.

The disadvantage of such a throttle handle is that with prolonged active driving, the hand begins to numb — since it is in tension due to the need to hold on to only the right half of the hand.

It is the most compact of the throttle grips and is therefore easier to install so that it does not interfere with another control element — the speed selector.

In fact, there is no definite answer to which throttle is better. Someone is used to riding a motorcycle and is completely satisfied with Full-twist, someone is used to gas triggering, and I, for example, like Half-twist.

Some bike electrification kits do not contain a display as a separate component — its function is performed by a display or indicator built into the throttle grip.

For example, this trigger-style throttle grip has a switch to turn on the bike and a battery voltage indicator.

Of course, when using such a throttle without a separate display, it will not be possible to select the degree of assistance in the assistant mode, but some simply do not use it.

Another option is a Full-twist throttle grip with LED battery level indicator and light switch. Although, this button can connect the function of turning on the controller and also do without the display.

In some cases, instead of a button, a lock with built-in contacts is installed — so that it is impossible to turn on the electric bike without a key.

In fact, there are quite a few varieties, I will not list all of them. Let’s better take a look inside some of them and see how everything works there.

First, let’s open the trigger type throttle handle. It consists of a rotating part, on which the trigger itself and the magnet are located. The spring provides a return to the handle.

When we press the handle, the magnet on the rotating part moves past the Hall sensor, when released, the spring forces it to move in the opposite direction.

In this case, the Hall sensor itself is wired to the board, and the board is inserted into a special groove in the handle body.

The Hall sensor here is analog, model 49E, in contrast to the digital one used in

The voltage at the sensor output depends on the supply voltage and changes in proportion to the strength of the magnetic field that acts on it.

And now, for comparison, consider a throttle grip device with a built-in voltage indicator and a switch. In order to get to the internal wiring, we unscrew 5 self-tapping screws on the case.

To the untrained reader, this view may seem like a tangle of wires, but it’s actually very simple.

There is a voltage indicator on the left. In the initial position, it does not show anything. When the e-bike is on, it displays the battery voltage in volts, which gives us a rough idea of when the battery will run out and how much more ride it can take.

The battery voltage (plus) comes along the yellow wire, then when the switch is turned on, it goes through the red wire to the voltage indicator and returns to the e-bike controller through the blue wire to turn it on.

The black wire is «GND», it is also called «ground» or «common wire». In fact, this is a minus of the battery, and it goes to the voltage indicator and to the central contact of the Hall sensor.

The red wire coming into the throttle handle is the supply voltage of the Hall sensor with a value of +5 volts. And through the green wire, the controller receives the output signal of the sensor, which changes depending on the position of the handle. Based on this signal, the controller determines how much power to supply to the engine.

I hope the information was useful for you or just interesting.

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