REV-Bikes Motors and Controllers

Geared Motors

Geared motors such as those in our 250w kits and the 'Power' 500w Kits, are great for lower power levels, as the Planetary Gear System within the motor helps you get better low-down torque (for acceleration and hill climbing) from a lower output motor.  The gears inside are made from a nylon composite material, to allow them to be durable and quiet.  The main benefit of the geared motor is total freewheel ability (so, zero rolling resistance), meaning you can pedal the bike easily if you are not using the battery.  They are also much less obvious than the larger Direct Drive electric bike motors, and weigh considerably less.

Direct Drive Motors

The 1000w+ motors are Direct-Drive, brushless, gearless DC pancake motors.  Direct Drive motors are used for higher power applications, as the nylon gears used (for quietness) in geared motors would not survive long at these higher power levels.  Unfortunately this means they do not totally freewheel; they will spin less times than a normal bike wheel once you stop accelerating or pedalling.  However, the magnetic nature of Direct Drive motors allows Regen Braking, meaning the system can capture some energy during braking or deceleration, and push it back into the battery (see below).  This type of motor is best for those who aren't really looking for any exercise when riding their e-bike, so for those who don't want to pedal.

We don't any longer offer them as standard options, but can supply 350w - 1000w direct drive motors for fitting into front wheel dropouts. 

Regenerative Braking (‘re-gen’)

(DIRECT DRIVE MOTORS ONLY) When your bike is going downhill beyond the motors' top speed, or you apply the brakes (presuming you've fitted the supplied brake levers with electrical signal coming out), direct drive motors will provide regen braking to assist you to slow down.  The system reverses the current flow of the motor and converts your kinetic energy back into electricity, which feeds back into your battery.  In addition to the benefit of assisting you to slow down, this helps you charge your battery whilst out and about (average 5% increase in range).
When using the regen braking, beware that you should not hold it on for prolonged periods, as it can overheat the controller if overdone.  If the battery is already fully charged, avoid using the regen brakes, and try to avoid switching straight to full throttle after using regen down a hill. 

Controllers

The controller is an important part of an e-bike kit.  It manages the requirements of the different system components, and has some safety features built in (ie, low-voltage cutouts to protect your battery when running flat).  Controllers are normally housed in bags supplied with our kits, with excess cabling and plugs stashed inside too, mounted somewhere on the the bike (in the triangle or under the seat normally).  Rack batteries include a controller box.  This means its a simple replacement if they fail, and you also have somewhere to stash any excess cabling from your kit.

Some motors have controllers mounted internally.  These are Programmable controllers, which can be plugged into your computer via USB to set various motor control parameters, and are multi voltage (24v, 36v or 48v) compatible.  However, due to low heat dissipation, these are prone to failure (why we no longer offer these motors).

We also sell external 'Magic' Controllers, which are multi-voltage programmable controllers, that can run vitually any e-bike motor up to 1000w (continuous output = 30amp, peak output = 60amp).  Plug changes may be required to run with other motors, but they do work for most motors.  Can be purchased with plug-compatible handlebar controls, call us if you require a complete set.. Or, we can fit plugs to match your existing setup if required.

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Geared Motor (250w or 500w)

Direct Drive Motor (with internal controller)

External 'Magic' Controller

 

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