10-08-2018, 03:51 PM | #1 |
Not Yet Wild
Join Date: Dec 2017
Posts: 71
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Motor Speed Sensor Issue
I'm hoping someone can help me out with an issue with my motor speed sensor. D&D won't offer any tech assistance what-so-ever due to contractile obligations.
The problem is that the sensor signal is about 1000 rpm low from the actual speed. For example, at 27 mph the speed sensor is reading 2900 rpm and all info I can come up with it should be running at 4,000 rpm with my 215/50 R13 tires (22" dia) and 10.35 gearing. Before I changed to the Alltrax controller it would do 27 with a controller max speed setting of 3700. Now with that speed setting I can do ~35 mph but my speed calculation suggests the motor speed is actually closer 5,500. Today I set a 3000 rpm speed limit and ran it hard with my computer attached logging the operational data. Log data showed the controller is doing it's thing limiting the motor speed to 3000 and I clocked 26-28 mph by gps. So, is the speed sensor in our motors designed to only work with the Sevcon or is something else amiss. If so, can I replace the sensor with a different one. How does one trouble shoot the sensor??? Thanks for any insight. |
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10-08-2018, 04:01 PM | #2 |
Gone Wild
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
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Re: Motor Speed Sensor Issue
If You have an Alltrax XCT Controller that is an easy fix, just change the pole count to 4-poles using the Alltrax software.
The cart should run better as well since the Alltrax uses the rpms to dynamically modify the motor field map. |
10-09-2018, 10:20 AM | #3 |
Not Yet Wild
Join Date: Dec 2017
Posts: 71
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Re: Motor Speed Sensor Issue
Thanks for the reply. I do have the controller set for 4 poles. When I first installed the Alltrax I didn't know which setting to use since neither Columbia nor D&D would speak with me about the motor. I first tried it at 2 poles but the speed was 50% of normal so I change to 4 pole and all was well. Has the same issue with the field map and only Alltrax would help.
I think the most frustrating thing about the swap is/was the lack of information and willingness to supply assistance. You would think I was asking for the keys to the universe and the silence has been deafening. Out friendly tech guy on the site has been great but I suspect there are limits to what he is allowed to speak of. Fortunately this speed sensor issue is a detail that, while nice to have resolved, is not a huge problem. |
10-09-2018, 02:28 PM | #4 | |
Not Yet Wild
Join Date: Dec 2017
Posts: 71
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Re: Motor Speed Sensor Issue
Quote:
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10-09-2018, 06:09 PM | #5 | |
Gone Wild
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
|
Re: Motor Speed Sensor Issue
Quote:
Make sure you have the other variables like gear ratio and tire diameter correct if You are calculating the rpm based on your speed. You could have a broken magnet or one that was modified on a bench grinder, did You already check the magnet? Otherwise replacing it with a known pole count sounds like a good idea. |
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10-11-2018, 01:45 PM | #6 | |
Not Yet Wild
Join Date: Dec 2017
Posts: 71
|
Re: Motor Speed Sensor Issue
Quote:
Also, before the controller change the car was indeed running at 26 mph with a controller speed setting of 3700 rpm. If I look at all the info and rounding the number to 4000 rpm with an 8 pole stetting, I would have 2000 rpm with 4 pole, and 3000 rpm with 6 poles. All this leads me to consider that Columbia is using a 6 pole magnet for use with the Sevcon controller. With 6 poles all the numbers line up. Now the problem with buying a new 8 pole magnet is how to find one that fits the D&D motor. I'll keep trying Columbia but the parts dept is tough to get hold of. Best guess is they have no idea of the pole count. On the upside, everything is working very well so this is just a detail that bothers me more than it should. I'll check with my tech and see if he might have a dead motor lying around that he can pull the magnet from and use as a reference. I'm open to any suggestions. |
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10-11-2018, 01:58 PM | #7 |
Gone Wild
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
|
Re: Motor Speed Sensor Issue
Post a picture of the magnet so we can see what it looks like.
There is a nice speed calculator on this site as well, it is under the "quick links" on the top right of the menu bar. |
10-16-2018, 01:56 PM | #8 | |
Not Yet Wild
Join Date: Dec 2017
Posts: 71
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Re: Motor Speed Sensor Issue
Quote:
Thanks for the tip on the speed calculator. Works great and confirmed what I thought I knew. |
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