Dan can I just check I've understood your throttle and pedelec set up.
You can run without pedelec attached and just use throttle on its' own, or you can install pedelec as well. With pedelec installed you can;
1. Use throttle as normal, with or without pedalling at any cadence.
2. Leave throttle alone and use the 3 position switch to choose max level of power input, with the actual power up to the max chosen being determined by cadence.
3. At any time you can over ride the pedelec system by using the throttle.
If you do over ride the pedelec system by applying the throttle (you gave example of shifting hub gear requires backing off pedals causing pedelec to stop and then restart which is not what you want when riding up hill!) does it also over ride the 3 position switch as well and just operate as if the there is no pedelec system at all.
Not exactly. Here's how it works:
(1) 3 "levels of assistance":
This feature is available at all times, whether throttle or crank sensor is used to control the ride speed. In the real-world, this translates into limiting the maximum speed that is achievable with each of the 3 levels of assistance.
The provided 3-stage thumb-switch is a selector for predefined speed limits, which values are specified in the controller firmware settings as percentages of the maximum power output (these thresholds can be configured using special PC software and a data cable between a USB port and the controller). The default fractional values are 50% 75% 100% but they give the wrong impression because the relationship with the perceived assistance is not linear.
The first level is only good for walking along the bike, or for cycling amongst pedestrians. I use the second level when climbing a serious hill (as the top speed cannot be reached anyway) or when riding side-by-side with slow-moving traffic. The third setting is obviously the most used one. In all 3 cases, the torque is the same so any level of assistance can be used to start from a standstill (as opposed to how mechanical gears work to translate leg power onto the road).
(2) Pedal Assist Sensor
This is a basic "pedelec" feature, because it doesn't measure the torque applied to the crank whilst pedaling, it only picks-up the crank's revolution rate. Assistance is turned on as soon as a certain rotational speed is reached, and it increases gradually and proportionally to the cadence.
The steeper the hill you want to climb, the higher the cadence you need (i.e. pedaling fast results in more power being fed to the hub motor). This contrasts with the throttle mode, whereby cycling at low cadence is possible, uphill or against the wind.
(3) Throttle
With this mode, one can manually fine-tune the assistance within the range of the currently selected assistance (out of the 3 predefined levels). Once activated, the throttle control overrides the PAS signal (Pedal Assist Sensor).
As it turns-out, riding with throttle is sub-optimal because of the mental effort and physical distraction required to "get it right", i.e. to strike the right balance between pedaling effort / choice of mechanical gear / suggested power output. I find it much easier to adjust my cadence to suit the PAS mode, as it's pretty much like a regular cycling pattern.
Furthermore, holding the throttle (thumb or handle) for more than a mile is not comfortable anyway. However, the throttle is very useful to kick-start the bike from a standstill, especially when one needs to quickly get out of the way at a junction with incoming traffic.
To conclude, I like to have both the PAS and throttle control at my disposal, in fact I think that they are indispensable. Whether I use one or the other, I find that listening to the motor's noise helps me determining the ideal human/assist ratio (the more silent Tongxin might be problematic
). Accurate feedback could be obtained from a watt-meter (Watts Up, Cycle Analyst, Turnigy, etc.), as the readings provide live information about power consumption / battery draw.
One note about riding steep hills: when I climb a stretch of road with assistance, I never stand on the pedals with a high gear (low cadence), because it produces uneven power surges to the crank and wheels. Instead, I remain seated with a low gear (higher cadence) and I apply constant torque through each pedal revolution (down and up strokes that activate opposed leg muscle groups), so that the motor delivers a constant amount of assistance for a given hill gradient. I consider this good practice, because when I don't follow it, I can hear the motor struggling to operate correctly.
Final note: a crank torque sensor would obviously offer a much better cycling experience, as there would be a direct connection between the rider's intent and the delivered assistance. This, coupled with a tilt sensor (mercury accelerometer, like on the Wii console or iPhone), would create a very natural pedelec feel: an e-bike that reacts instantly to the environment, anticipating our every moves
Cheers, Dan