Removing controller from aluminium casing

[Gooseman]

I purchased a plastic controller box which fixes to the frame but there is not enough room to house the connectors as well if left it inside its aluminium casing. As in the picture i am thinking of placing directly on the plastic case and using silicon to secure it. Is this likely to melt through the plastic box and be a bad idea?

 

[davell]

Not certain but I think the aluminium casing also acts as a heat sink. Removing it could result in overlheating.

 

[vfr400]

Yes, you need the aluminium box as a heat sink. Put the controller in one of those under the saddle tool-bags. You can hide all the excess wire in there too, plus you can stick your puncture kit in there.

 

[Gooseman]

Yes, you need the aluminium box as a heat sink. Put the controller in one of those under the saddle tool-bags. You can hide all the excess wire in there too, plus you can stick your puncture kit in there.

Thanks great idea will save alot of hassle .

 

[Andy-Mat]

I purchased a plastic controller box which fixes to the frame but there is not enough room to house the connectors as well if left it inside its aluminium casing. As in the picture i am thinking of placing directly on the plastic case and using silicon to secure it. Is this likely to melt through the plastic box and be a bad idea?
View attachment 36409

It needs not only to be in its original alu box, but some air cooling it is also needed to keep the MOSFETs within their allowed temperature range.
Andy

 

[vfr400]

It needs not only to be in its original alu box, but some air cooling it is also needed to keep the MOSFETs within their allowed temperature range.
Andy

It'll be fine in the bag.

 

[Andy-Mat]

It'll be fine in the bag.

Slight overheating of MOSFETS does not usually cause instant failures, but the cooler they run, the longer the lifespan of such components....
MOSFETs are often used in an ON/OFF mode, which keeps them relatively cool, but depending upon the way the controller was designed, may be different, eg. switching only say half on for speed control.
I have never had the chance to see a schematic for a Chinese controller, which is why my controller is air cooled, and clamped to the bike frame (aluminium) as well.
But it may not be needed if it runs cool and a cloth bag is then OK....
Andy

 

[Gooseman]

I have never had the chance to see a schematic for a Chinese controller, which is why my controller is air cooled, and clamped to the bike frame (aluminium) as well.
Andy

Do you mean like the one is this picture and have you had any issues with water getting in like that?

 

[vfr400]

Slight overheating of MOSFETS does not usually cause instant failures, but the cooler they run, the longer the lifespan of such components....
MOSFETs are often used in an ON/OFF mode, which keeps them relatively cool, but depending upon the way the controller was designed, may be different, eg. switching only say half on for speed control.
I have never had the chance to see a schematic for a Chinese controller, which is why my controller is air cooled, and clamped to the bike frame (aluminium) as well.
But it may not be needed if it runs cool and a cloth bag is then OK....
Andy

I despair at some of your posts. There are practical solutions that have been proven to work for many years over a range of bikes - even provided by mass-production kit suppliers, and there's bullshit theory.

 

[Sturmey]

....I have never had the chance to see a schematic for a Chinese controller, ....

Hi Andy. I have attached a (general) schematic of a KT controller.

 

[Andy-Mat]

Do you mean like the one is this picture and have you had any issues with water getting in like that?

Inside the frame!
I neglected to mention that, but as most of them are inside something on a bike, I did not think that anyone would need telling, my bad!
Now you know!
And as my controller was fully sealed up, and if this one is too, I suppose that outside the frame could be even better....it certainly should give the maximum possible life to the electronics temperature wise, provided no water can find its way in.....
I use silicone 705 to seal stuff up, which is cheaply available on ebay, with a tiny nozzle, if anyone is looking for such great stuff! It also accepts high temperature, glues like "sh*t to a blanket" if the surfaces are properly cleaned first!
There are cheaper sellers than this one, if you wait for it to arrive from China....

705Temperature Clear Silicone Rubber Insulating Electronic Sealant Adhesive Glue | eBay

Find many great new & used options and get the best deals for 705Temperature Clear Silicone Rubber Insulating Electronic Sealant Adhesive Glue at the best online prices at eBay! Free delivery for many products!

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regards
Andy

 

[Andy-Mat]

I despair at some of your posts. There are practical solutions that have been proven to work for many years over a range of bikes - even provided by mass-production kit suppliers, and there's bullshit theory.

I am so "impressed" with your honesty that you acknowledge your despair, as your "despair" here, simply demonstrates to all, (those with REAL KNOWLEDGE of the subject), your lack of both experience and expert knowledge....and even simple good manners....
What a waste of a life!!
Have a great day anyway, as I certainly am!!
Andy
PS. You are most welcome to COMPLETELY ignore all my posts in the future, if you so wish, but if you don't or better said CAN'T, I will always answer you, as ever, as I see fit! OK?

 

[Andy-Mat]

Hi Andy. I have attached a (general) schematic of a KT controller.

Many thanks, good reading for this evening.
Andy