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Mobility scooter speed controller

How does the speed controller potentiometer control the forwards and backwards motion as well as the speed? Where can I find circuit diagrams for controllers? Most info on the web shows a wiring diagram to connect the motor / controller / battery - none on the theory behind the controller.

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Peter Skilton Wondering what you are up to? :-) Is this just a generic question about the speed controllers in general or a specific product?

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I recondition mobility scooters (at my own expense) and loan them out through my church to pensioners that cannot afford one of their own. The faults judged uneconomic to repair by professional repairers can often be fixed if time is not a factor and usually come to motor/battery/charger replacement and often making a good one out of two duff ones is a solution, except for batteries, I always replace those. The current query is for a 1990s Gofer with a controller fault. I phoned the controller Co. and they sold off the mobility side to a guy who committed suicide. They said the dead guy's one man company has folded.

I can see that the DC motor directional control is achieved by a a variable voltage from the handlebar mounted 5k variable resistor triggering either relay A or relay B but that input voltage has to be stabilised to work reliably and I don't see a stabilising circuit so maybe I am not interpreting the logic correctly. I suspect all controllers work the same way - so I look for more basic info.

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Hi Christopher. I have two machines in at present for reconditioning. One was built in the UK and the other in China but both controller boxes have almost identical variable resistors on the handlebars so obviously work in identical manners. So my enquiry is generic. The puzzle is that they must work by varying the voltage but logic suggests that they can only reference a voltage if it is from a stabilised source - but there is no apparent stabiliser on the circuit board! Surely someone some where wrote a book or paper on mobility scooter control systems!

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Hi,

Can anyone advise me please? I have an Ultralite 380. The battery is fully charged and the terminals seem fine. The power gets through when the key is turned on but the scooter won't move.

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You need more info Nise to diagnose what is faulty - such as what were you doing when it died? Is the battery voltage 13.5v? How old is the battery? If you separate the motor from the battery do you have voltage at the battery side connector and continuity through the motor windings connector? Is there a power disconnect switch (so you can push the scooter) - is it broken or seized? More info Nise

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my scooter is ew38 ewheels it went into the swimming pool batteries are good will not roll seems like motor locked up has power when you turn switch on but nothing works? I AM IN CALIFORINA .

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it is a matter of a process of elimination. It may be a locked up motor if it sat a while after the incident. Or maybe a shorted motor if operation was attempted b4 it dried out. A shorted motor is very hard to turn. I would attempt to monitor the output of the controller when disconnected from the motors.

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Hi Jack. Scooter in pool is a major problem. So many things could go wrong. To see if the motor rotates OK, you need to operate the lever that disconnects the motor from the brake. It is the lever under the seat that allows you to manually push the scooter. If you operate that, then push the scooter, it should turn the motor over and that will confirm whether or not it is seized. The reason that it is not free when you turn the key is because the brake (clutch) is not receiving power. It has a micro switch on it and you need to measure (with multi meter) if current is going in to the brake windings. If current is present one one side but not the other - then the switch is burnt out or the brake is burnt out. If the is no current either side of the switch then the controller or battery circuit system is faulty.

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Peter Skilton just for starters I'd recommend you read through this Development of a Control System for a Power Wheelchair Trainer. It has a lot of really good information (including the motor controller).

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Firstly the movement of the pot is monitored in most controllers by a embedded processor such as a PIC 16 right upto the latest embedded ic’s , they can also be found in Car E.C.U.

Once the processor is satisfied that Brake, Motor etc are connected and given the right resistance, It will activate a relay and a mosfet power-driver known as a HIP4082 etc,.

I suggest you lookup the PIC chips and look at application notes regarding driving a electric motor , the theory will be explained in detail..

Most controllers can be repaired cheaply..

Regards

Rob

GewizRepairs.co.uk

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The problem is that it is a 20 year old unit and before dedicated processors. The logic is made up with a circuit board and discrete components - hence my original request for info on theory rather than circuit diagrams. I have to get in to the mind of the original designer (now deceased).

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hi Peter whats the name (company) of the controller ? a photo ?

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my handicap scooter got wet controller went out had it in the shop but could not fix it and they put another controller in but still dose not work?

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Hi Jack. Your scooter drive system has multiple parts. The first thing to consider is - is the machine completely dead? If so, suspect the batteries or cabling - check with a multi-meter. If they check out OK, then it is the controller or the plugs associated with it. The motor - the strongest item in the system is unlikely to be affected by rain water except for the clutch which has a micro switch on it. If that has burnt out then the controller should send a signal to a light on the handlebar cluster that flashes a number of times. You need to count the number of flashes and Google the scooter maker and ask him for a fault chart. If the machine is not completely dead then the control head at the handle bars has a variable resistor (normally 5K) and some fixed resistors and diodes. Check with a multi-meter. You say that the shop has replaced the control box - actually they are very water tight and if it is only rain water, unlikely to be faulty - if your scooter actually went under water in a flood then it is probably a 'write off'. So .... if its dead - check power source system (i.e. battery circuits), if not dead - suspect circuit in wiring cluster at the handle bars. If you give us more information on what happened maybe we can be more specific. What country are you in? What make is the scooter? Peter Skilton.

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Hi Jack. There is another correspondent on the Fault Section who's computer address is GewizRepairs.co.uk.

He has - on his web site - an instruction book issued by Shoprider Co. that lists every fault I have ever found on a mobility scooter, and more importantly - how to fix it. He is a great guy, he will help you even better than I can. Peter Skilton in Australia

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I'm looking up GewizRepairs now. Thanks for the advice!

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