Tag Archives: bldc motor

bldc motor for electric bike

Posted by on December 7, 2022 Comments Off on bldc motor for electric bike

Because of lower noise, more powerful,longer life.Now bldc motors are popular for electric bikes.

This motor can be easily built into a wheel hub,called brushless hub motor or done a chain drive,named stepper motor.Stepper motor is more powerful than brushless hub motor.

As all known,hub motor is easy to convert e-bike,but for bldc motor,it’s so easy to convert.You should use a chain to drive wheel.
We have three kinds of bldc motors.It aslo is made up of rotor winding,hall sensor,bearings,axis,gears.

Because of gear drive,it’s more powerful than common brushless hub motor.
1.BLD-500 bldc motor Net weight:6.08kg

2.BLD-650 bldc motor Net weight:6.53kg

3.BLD-800 bldc motor Net weight:8.8kg

replace hall sensor for 750w hub motor

Posted by on May 11, 2022 Comments Off on replace hall sensor for 750w hub motor

The hall sensor is a transducer that varies its output voltage in response to a magnetic field. Hall sensors are used for proximity switching, positioning, speed detection, and current sensing applications. Three phase bike motor has three hall sensors inside that are used for electric bike widely.

36V 250W brushless geared motor is popular in Europe, but in North America, people like 36V 750W hub motor more. More and more people order and enjoy these two types of DC hub motors that are called classic electric bike motors. Now they have received by most of customers because of good quality.

But when ride this hub motor bike and climb hill for a long time. Sometimes over current or over head will break motor controller’s MOSFET or hall sensor.

Hall sensor is broken. The hub motor can’t work. Unless your controller can drive sensor-less motor. Buy a new motor, cost more.

Replace hall sensor, cost less. Below we first instruct one type of 750w electric bike motor .

If hall sensor is broken, power on battery, you will find battery gauge works, horn works, lights work, everything is good, except when you turn your throttle, the hub motor wheel can’t run.

Step 1:
Retest this hub motor and make sure it does be broken. Do you have voltmeter?
Still connect all wires and power on.

First measure 6-pin hall sensor plug, the voltage as below:
1.The voltage of red and black is about 4.5V;
2.The voltage of yellow and black is about 4.5V or 0V;(use hand to turn hub motor, the voltage will change from 0V-4.5V)
3.The voltage of green and black is about 4.5V or 0V;(use hand to turn hub motor, the voltage will change from 0V-4.5V)
4.The voltage of blue and black is about 0V or 4.5(use hand to turn hub motor, the voltage will change from 4.5V-0V)
If you can get above data it’s no problem with bike conversion kit system. If the voltage of Item 2 (yellow and black wires)can’t change from 0V-4.5V,Please replace this hall has a yellow wire connect.

You should prepare some tools and material:
1.Hexagon wrench (Necessary)
2.Hammer (Necessary)
3.Screwdriver
4.electric iron
5.A-B glue
6.insulated paper, insulated wire
7.scissors
8.New hall sensor

Step 2:
Take off nuts and gasket on axis and use hexagon wrench to loose 16 screws.

Step 3:
Make the electric bike motor stand and cable is bent inside. Left hand hold the hub motor and use hammer to knock the axis.

Step 4:
After some knock, the cover will take off hub.

Step 5:
Use the same way to knock the other axis, the other cover will also take off hub.

Step 6:
When both side covers are off hub, next we should take out the rotor-winding. Make the axis stands on the ground, both hands press hub motor, the rotor-winding will out of hub.

Step 7:
There are three hall sensor in three grooves around the rotor.
Use scissors to remove insulated wire and insulated paper. You will find 9-pin(three hall sensor)connect to PCB on rotor-winding. Each hall has three pin: 1:+ , 2:- ; 3:signal
For example:
Hall A: 1:+ , 2:- ; 3:Yellow wire
Hall B: 1:+ , 2:- ; 3:Blue wire
Hall C: 1:+ , 2:- ; 3:Green wire

Step 8:
Just now had known yellow wire hall sensor was broken. Please use electric iron to remove Hall A and use A-B glue to fix new hall sensor. Use insulated paper, insulated wire to fix PCB. Then re-build this hub motor.

Step 9:
Test as step 1.If can get the data from each hall sensor. Congratulate.

Power on battery, the hub motor wheel works.

strange problem with 5000W bldc motor

Posted by on January 26, 2022 Comments Off on strange problem with 5000W bldc motor

Some very strange problem with 48V 5000W bldc motor. Purchased six motors half a year ago, for EV project. We managed to get to the actual testing with your motors only now.

When started our tests, we faced very strange problem.

Need help and suggestion on what the reason of problem can be.
We have or own BLDC controller, with three half-bridge, PWM for low
gates and block commutation for high gates. Everything works great,
but motor does not start in two particular positions of rotor.

If refer to the wiring diagram, motor does not start when try to
rotate it clockwise (if I look into shaft) when:

1) Hall sensor with yellow wire is activated, others passive
2) Both hall sensors with yellow and green wires are activated, blue
is passive.

When try to run it counterclockwise it doesn’t start in two other
positions when:

1) Hall sensor with blue wire is activated, others passive
2) Both hall sensors with blue and green wires are activated, yellow
is passive.

Please note that in both cases the positions where motor doesn’t start
are consequent.

Motor starts perfectly in all other positions of Halls. If motor
started in some other position, it rotates without problems. I think
it simply passes the problem angles due to inertia it has.

I checked, double and triple checked my truth table and it is okay.
It works great on some other BLDC motors I have.

Then I thought that this particular motor has problems in its wrings
inside and tried other motors I purchased from you. All six motors
show the same problem, in the same positions.

So I have two possibilities now:

1) There are some “dead” zones inside motor which I’m not aware of. I
think this is an issue. If so, please let me know how to overcome it.

2) Something wrong with my controller. But this is unlikely. Firstly, it
works with other BLDC motors without problems. Secondly, your motor
doesn’t start in two consequent positions of rotor. If algorithm is
wrong, then it will fail on some opposite positions, not consequent.

Please, let me your thoughts on this problem, as I’m starting to think
that there is some secret in motors that I don’t understand!

Any help will be greatly appreciated.

And please note that letting aside this above mentioned problem, your
motors are pure gold and we are going to order some good amount for
our EV factory in next months, if we settle this very problem I talk
of.

Bldc stepper motor for electric bike

Posted by on January 15, 2022 Comments Off on Bldc stepper motor for electric bike

In the subsection of section Classification of electric bikes we looked at options for motors used in electric bicycles, their positive and negative sides.

Let’s try to analyze and compare the characteristics of electric motors (bldc hub motor and bldc stepper motor)from one well-known manufacturers: Leaf Motor (China).

Leaf Motor produces sets with a motor-wheels, and the other kits that use a chain drive.
The analysis will be based on data from well-known owners of electric bikes site EValbum, the characteristics of the manufacturer, and other sources on the Internet. Therefore all figures are approximate, and the findings are an expression of opinion ePowerBikes.ru

As stated by bldc hub motor, voltage motor-wheel independent maximum speed:24V – 25 km / h, 36V – 32 km / h, 48 V – 50 km / h. These data are confirmed by practical measurements elektrovelosipedistov. The maximum velocity at the start line set bldc stepper with 42 km / h and end with 120 km / h. Those cyclists who speed up to 30 miles is enough, can choose a motor-wheel 24V,36V,or 48V.

For practical information, electric bikes with a motor-wheel 36V 500W and lithium-phosphate battery 10Ach a maximum speed of 32 km / h and can cover a distance of 50 km. For those who want to ‘fly’ at speeds above 50 km / h, suitable set of Leafmotor 601kit-1 48V 1000W e bike kit.

Compare sets with the same maximum speed – 45 km / h – a new set 601kit-1 48V 1000W bldc hub motor and bldc stepper 48V 500W. Based on the characteristics of graphs,we choose the rate at which engines operate most efficiently, it is 40 km / h for both.

For the same power consumption in this mode – 420-440 watts, at the time of bldc stepper motor is a little more, but this is neglected. It turns out that energy costs are the same at a speed of 40 km / h. We obtain a theoretical figure 10.5 Wh / km, although in practice the number is likely to be greater. Now suppose that we face a steep hill. The maximum torque developed HBL hub motor – 30 Nm, bldc stepper motor – 38 Nm.

For the calculation we use a calculator elektrovelosipedista. Let Curb weight of a bicycle with the stepper motor – 100 kg, the rise of 7% of 3.5 km. To overcome this recovery time is needed more than 26 Nm on the wheel 26. ” Power expended by the motor-wheels 601kit-1 e bike kit is more than 1060 W at a speed of 35 km / h. Total energy costs – 106 Wh.

What makes it with bldc stepper-kit? He switched to the lowest gear, increasing time and decreasing the rate of 2.4 times (for cassettes with a maximum star 34t). At 2600 revs / min, torque on the shaft of the gearbox – 11 lb lost by power – 390 watts, speed – 14.5 km / h. Cost of energy to overcome lift – 94 Wh. Switching gears allow the rider to use the bldc stepper with the maximum efficiency of ~ 83% versus 73% for motor-wheels 601kit-1. As you know, the availability of transmission system for a bicycle greatly expands the range of effective use of a set of bldc stepper motor. These are one of the best available right now,s o if your´re looking for one, check it out. 9-14 cassette on the wheel 26 “will change the torque of 6 to 60 Nm and a speed in the range of 11.5-45 km / h (about 2100-2900 revs / min) at an efficiency of above 80% (included efficiency gearbox and chain drive). Efficiency of the motor-wheels 601kit-1 has a maximum value of 78% of torque 10-16 Nm.

It is logical that upon arrival at the ideal surface Bonneville Salt Lake in Utah, at 40 km / h, both test sets will spend the same amount of energy. But as soon as the trial will move to an area with hilly terrain, a set of bldc stepper will be more economical than 601kit-1, and of course will be able to overcome the ups who his opponent will not under force.

We note again that the higher efficiency is achieved when using leafmotor’s bldc stepper motor in the range of maximum efficiency, extended thanks to gear bike.

hub motor and the BLDC motor

Posted by on January 13, 2022 Comments Off on hub motor and the BLDC motor

Synchronous and BLDC motor are AC powered motor is AC power supply by 50 weeks and turn. BLDC motor is the stator into the alternating current, a rotating magnetic field, and the rotor magnetic field generated by the sensor, so that two magnetic field, along with the rotor and the stator rotating magnetic field rotation. Which slow the rotor than the stator rotating magnetic field, there is a deterioration of sync so called asynchronous machine. The hub motor stators with the BLDC motor, the rotor is formed artificially by adding the same DC magnetic field, so that the rotor on the stator rotating magnetic field along with the simultaneous turn before said hub motor. BLDC motor is simple, low cost, easy to install, use and maintenance. So widely used. Disadvantage and low efficiency, low power factor on the grid negative. The hub motor is a capacitive load, high efficiency, can improve the power factor, multi-purpose large-scale mining did not prepare.

hub motor and the BLDC motor stator windings are the same, the main difference is that the rotor structure. hub motor’s rotor with DC excitation windings, so they need external excitation power, the introduction of current through the slip ring; the BLDC motor’s rotor is short-circuited winding, the current generated by electromagnetic induction. In contrast, hub motor is more complex, high cost.

Uses: hub motor generators are mostly used in large-scale applications. The BLDC motor is used in almost all motor applications. hub motor can be flexible and adjust the input side of the excitation voltage and current phase, that is, the power factor; BLDC motor power factor is not adjustable, generally between 0.75-0.85, so in some large factories, BLDC motor used more often, you can attach a hub motor to do tune cameras, used to adjust the factory interface with the grid power factor. However, the hub motor, high cost and maintenance workload, compensation is now generally use capacitive power factor.

Comparison of motor start-up mode

1 Direct start: by the power capacity limit

2 series reactor startup: starting torque is not easy to lead, may be secondary impacts.

3. Autotransformer start: start a buck, there are secondary impacts, adjustable voltage range is limited.

4 soft-start variable resistance: thermal resistance, fluid resistance,

5. Magnetron soft start: adjust the conduction angle of SCR power controller to regulate the flux of change.

Soft-start frequency: AC – DC – AC mode, the voltage can be controlled to become the frequency AC power for high voltage motors.

Motor star delta starter

1 When the load on the motor starting torque is not critical but also limit the motor starting current and the motor to meet the 380V / Δ wiring conditions in order to start using delta method;

2 The method is: when the motor starts the motor connected as a star after a successful connection when the motor starts to divert into a triangular electrical wiring (by double-throw switch quickly switch);

3 due to motor starting current and power supply voltage to provide start-up time is proportional to the current full-voltage start-up current is only 1 / 3, but only full voltage starting torque starting torque for 1 / 3 Star delta starter, is a step-down start it at the expense of power in exchange for reducing the cost of starting current to achieve. It can not be dismissed and the size of the motor power required to determine whether a star delta starter, but also to see what kind of load, generally need to start light load, heavy load operation can still be a star delta starter, under normal circumstances, squirrel-cage motor starting current is 5-7 times the running current, and voltage requirements of the grid is generally plus or minus 10% (I remember) in order not to form the grid voltage is too large so the impact of a star delta starter, the general requirements in squirrel-cage motors power transformer rated power of more than 10% will use star delta starter. Only squirrel-cage motor was a star delta starter.

BLDC Motor application introduction

Posted by on January 7, 2022 Comments Off on BLDC Motor application introduction

BLDC Motor is an DC motor, the load speed and frequency of the received power ratio is not constant relationship. Also changes with the size of the load. The greater the load torque, rotor speed, the lower. BLDC Motor, including induction motors, doubly-fed BLDC Motor and AC commutator motor. The most widely used induction motor, without misleading or confusing in the case, generally known as the induction motor BLDC Motor.

Ordinary BLDC Motor stator windings connected AC power grid, the rotor windings and no other power connections. Therefore, it has a simple structure, manufacture, use, and easy maintenance, reliable operation and low quality, and low cost.

Hub Motor with high efficiency and good performance characteristics, from no load to full load range almost constant speed, the majority of industrial and agricultural production to meet the requirements of mechanical transmission. Hub Motor protection is also easy to generate a variety of school types, in order to adapt to different environmental conditions need to Hub Motor is running, you must learn from the reactive excitation power grid, the grid power factor deterioration. Therefore, the drive ball mill, compressors and other high-power, low-speed machinery and equipment, often used synchronous motor.

Because BLDC Motor speed rotating magnetic field speed with a certain deterioration in the relationship, its speed performance is poor (except AC commutator motors).

BLDC motor and brushless motor

Posted by on January 7, 2022 Comments Off on BLDC motor and brushless motor

  For a long time, there is a big battery technology R & D bottlenecks, many countries have committed to developing higher-performance electric car motor vehicle in order to obtain improved performance, China is no exception.

    As early as four years ago, the market is still in the majority of electric bicycles use BLDC motor stage. BLDC motor uses a mechanical commutation, the control system technology, less demanding, lower cost than the brushless motor, BLDC motor starting torque is slightly larger than the brushless motor.

    BLDC motor has several weaknesses: short life, noise, and low efficiency. Short life because it uses carbon brush, turning the process easier to damage. Also wear a lot of toner dust generated, these dust fall gear oil, gear oil to speed up the drying, to further increase the motor noise.

    BLDC motor used once a year or so to replace carbon brushes, carbon brushes replaced after one charge mileage car bought less than two-thirds of the time, but also in the climbing area seem less motivated, even burn control. This is because the carbon brush replacement motor, the commutator also grind a groove, so that the contact area to reduce the carbon brush, carbon brush of poor contact will spark power and speed and oxidation of copper commutator, resulting in the undesirable phenomenon.

    brushless motor is a special kind of DC motor, it uses built-in sensor plus electronic commutator method for electronic commutation, brushless motor mainly to eliminate brush wear and brush contact noise generated.

    From the low-speed electric vehicles since the advent of the motor, brush and brushless motor of the dispute has been no stop. Comparing both, brushless motor really is superior to BLDC motor, brushless motor also known for its excellent performance for the general consumer acceptance. Currently, almost all electric bikes are used a brushless motor, brushless motor instead of BLDC motor is a must.

Domestic electric BLDC motor

Posted by on January 7, 2022 Comments Off on Domestic electric BLDC motor

 The so-called nanotechnology, refers to the scale of 0.1-100 nm, the study of electrons, atoms and molecules within the law of motion and features a new technology. Scientists in the study of matter in the process, found in the nanometer scale of a few isolated, several dozens of atoms or molecules can be significantly demonstrated many new features, and making use of these features have specific functions for the technical , is called nanotechnology. Nanotechnology manufacturing of electronic devices, its performance is much better than traditional electronic devices: work fast, low power consumption, small size, light weight, electronic volume and weight greatly reduced. BLDC motor of the leader, the United Kingdom motor using nano-technology, successfully developed a new generation of internationally efficient brushless motor. After loading the measured electric car specialty stores, BLDC motor with high efficiency, low temperature rise, ride comfort, good stability, a fundamental solution to the electric vehicle motor efficiency due to low mileage due to riding too close, climbing implementation of the bridge, high energy and many other defects, the electric car race minds at ease.

    Currently, the motor was first applied to the domestic electric car companies, the first new type of motor spirit has been through Shanghai Electric Vehicle Co., Ltd. All buyout. The BLDC motor material is ultra, ultra-fine particles of new high-strength metal materials, with a special magnetic compound treatment, with superior quality, the internal magnetic field and the motor running without moving parts, compact, no travel restrictions for linear motion and circular movement with unmatched precision. Expert Review of its features love: love of electric vehicles using Aoli Xi BLDC motor, the motor will never rust, runs smoother ride, starting more stable. Shanghai Electric Vehicle Co., Ltd. spirits through the introduction of this technology developed by the “love” brand electric cars once sold in the market. When brand new cars are out of the budget, you can always cars van nuys ca.

BLDC motor control technology

Posted by on January 7, 2022 Comments Off on BLDC motor control technology

    In 2005, BLDC motor controller was developed, improved and upgraded to address the existing weaknesses in several electric vehicles, vehicle design to meet the consumers and the increasing demand for vehicle performance. It avoids the same maximum rated power output of a long, sustained the same frequency to reduce the impact of the motor, motor coordination and other systems, electric cars and stable work, greatly extending the life of electric vehicles.

    Equipped with a BLDC motor controller for electric vehicles in the cycling process, the inverter controller and inverter composed of high-efficiency motor power system, take advantage of low current, high-torque theory, in the process of riding in a timely manner according to traffic and load to adjust the output power .

    This technology works, the electric car start, climbing, a small motor current, torque, and increases the climbing ability and more power; and on a level road, the standard load driving the motor to a small current, high efficiency work, so fast, low power consumption, extend the continued line mileage.

    Install the BLDC motor system of the electric car as long as a power supply and speed, the car was immediately driven, and demonstrated a remarkable strong force, and unlike most of the electric car start when they “struggle” was a difficult time crawling This is the BLDC motor technology advantage.

    In July 2005, the Group introduced three BLDC motor MACAT electric cars, are very popular. Taiwan Tianjin growth of electric cars with electronic features brushless motor control system — electronic CVT systems, but also uses the same technology. This new motor system increases the motor torque constant, reducing the overload point, the motor phase current context, to effectively improve the speed of the motor rated load point.

    2007 by Locomotive Co., Ltd. Qing long developed similar to the motorcycle gear with three power electric cars is based on such frequency control technology.

    This technology effectively improve the electric vehicle drive system features a certain extent, solve the electric vehicle the problem of poor climbing ability, and easy manipulation of the user, complete electric car downshift speed and overall performance has made great breakthroughs .

BLDC motor vehicle idling is a component

Posted by on January 7, 2022 Comments Off on BLDC motor vehicle idling is a component

BLDC motor vehicle idling is a component. Referred to as idle the engine idling. Its role is: idle, according to the level of the engine temperature and load size, change the idle air channel cross-sectional area of ​​the engine under different conditions have the best idle speed.

BLDC motor controller is mainly used to bear the car idle, and its purpose is to be used according to the idle time to adjust the idle speed of engine load. Idle stepper motor mounted on the throttle body from the engine controller to control engine idle speed, engine speed deviation from the idle, the valve regulating flow from section to control the intake manifold into the air by the mechanical operation of the accelerator pedal steel wire rope . Throttle body with a bypass air channel, to provide air in the engine idling (when the throttle is closed). BLDC motor automatically pivot into his bypass air tract, which regulate air flow through the engine controller according to a variety of sensor inputs, the use of mobile automated BLDC motor controller for pivot out of the bypass air channel adjust engine idle speed. When the ignition key to open position, automatically BLDC motor to work. The switch signal input ECU, the engine is in idle perception condition. At the same time, real-time position in which the motor from the motor position sensor feedback to the ECU.