Search found 283 matches

by hias9
Sep 20 2021 2:21pm
Forum: EBike Technical
Topic: will statorade overheat my magnets?
Replies: 7
Views: 156

Re: will statorade overheat my magnets?

From my experience I can say that 100 degrees Celsius at the windings is not enough to do any permanent damage to the magnets. Most likely the magnets used in your motor are rated for 120 or 150 degrees Celsius maximum temperature. The hottest part is normally at the windings and that is where the t...
by hias9
Sep 18 2021 6:15pm
Forum: Items Wanted
Topic: New BBS02 - No controller/display required
Replies: 0
Views: 73

New BBS02 - No controller/display required

I am looking for a new BBS02 for 68-73mm BB. I don't need the internal controller or a display because I will use an external controller.

Best would be if it's located within the EU.
by hias9
Aug 26 2021 9:27pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

That is very likely what happened. But the strange thing is that according to the milliohmmeter there is no short in the windings. One strand (it has 21 strands in parallel) was cut by the heat when the ropes that keep the windings in place burned. So resistance is not exactly equal over the 3 combi...
by hias9
Aug 25 2021 3:57am
Forum: Battery Technology
Topic: Flatpack S help
Replies: 1
Views: 138

Re: Flatpack S help

Does anybody know how to open a Flatpack S?
If I remove the six T10 screws and put the black screw on the front side into unlock position, it is still fixed at that black screw and I cannot open the case.
by hias9
Aug 18 2021 7:43pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

Yes, this would increase the eddy losses by a lot. But how can I measure if the enamel between the lamination has burned?
I would have expected the enamel not to burn before reaching much higher temperatures.
The laminations are electrically connected to each other (also on the new stator).
by hias9
Aug 18 2021 3:08pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

It’s electrically conductive and electrically there is a short between the laminations, but that’s also the case on the new stator.
by hias9
Aug 18 2021 2:02pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

A QS205 would have a negative impact on weight, weight balance and handling, so I am trying to avoid that. The bike with batteries weights only 80lbs. I will have these motors rewinded with high quality wire and with the stuff that failed below 150 degrees celsius replaced by parts that work up to a...
by hias9
Aug 18 2021 1:14pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

https://i.ibb.co/RNMNhz0/DSC-3703.jpg https://i.ibb.co/P543T4Q/DSC-3705.jpg https://i.ibb.co/8BV6XVT/DSC-3706.jpg https://i.ibb.co/Yk3mz6m/DSC-3707.jpg https://i.ibb.co/jJbyjMh/DSC-3708.jpg https://i.ibb.co/T8xKtr5/DSC-3709.jpg https://i.ibb.co/BwWsCFj/DSC-3711.jpg https://i.ibb.co/1vSj4Nh/DSC-3712...
by hias9
Aug 18 2021 12:37pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

I finally had time to open the motor and replaced the stator by a new one. Seems like the magnets are absolutely fine. Kv was only slightly increased and is back to normal now. The old stator which I ran up to 150 degrees Celsius had extremely increased eddy losses: 1300W consumption at 950rpm 350W ...
by hias9
Aug 15 2021 9:28am
Forum: Battery Technology
Topic: ULtra Compact 1800W charger + Eltek programming
Replies: 321
Views: 62832

Re: ULtra Compact 1800W charger + Eltek programming

How do you open a Flatpack S?
I removed the 6 long T10 screws and put the black screw next to the LEDs into unlock Position, but it's still fixed at the black screw.
by hias9
Aug 14 2021 7:52am
Forum: Battery Technology
Topic: ULtra Compact 1800W charger + Eltek programming
Replies: 321
Views: 62832

Re: ULtra Compact 1800W charger + Eltek programming

nrconder@gmail.com wrote:
Aug 14 2021 2:09am
hias9 wrote:
Aug 13 2021 9:44pm
Does anybody know what kind of bit is required to remove the long screws of the Flatpack S?
Torx T15 is too large and T10 too small.
The bit I used was marked "T10H"
Yes, a T10 fits. Sorry, it was already late yesterday.
by hias9
Aug 13 2021 9:44pm
Forum: Battery Technology
Topic: ULtra Compact 1800W charger + Eltek programming
Replies: 321
Views: 62832

Re: ULtra Compact 1800W charger + Eltek programming

Does anybody know what kind of bit is required to remove the long screws of the Flatpack S?
Torx T15 is too large and T10 too small.
by hias9
Aug 10 2021 7:04pm
Forum: EBike Technical
Topic: how to know if you're current or voltage limited for top speed ?
Replies: 12
Views: 353

Re: how to know if you're current or voltage limited for top speed ?

I don’t know why to make it so complicated. If one can still draw max. amps or watts at top speed, it’s the current that’s limiting. If amps and watts at top speed are lower than peak it’s the voltage that is limiting. For example: 20mph full throttle it draws 2000W, 35mph top speed it draws 1200W: ...
by hias9
Aug 10 2021 8:58am
Forum: EBike Technical
Topic: Sealing Phase Wires Exit
Replies: 3
Views: 199

Re: Sealing Phase Wires Exit

I am using more than the recommended 8ml Statorade so heat transfer is also good at high rpms. I don't care about a little increase in drag. While the motor is turning the ferrofluid gets splashed around. It also goes to the phase wire insulations and bearings outer ring.
by hias9
Aug 10 2021 8:34am
Forum: EBike Technical
Topic: how to know if you're current or voltage limited for top speed ?
Replies: 12
Views: 353

Re: how to know if you're current or voltage limited for top speed ?

Most likely (except current/power limit is set very low), your top speed is limited by voltage. Are you using a display which shows drawn battery amperes or watts? If the motor draws less amps or watts at top speed than at it's peak (which is the case in most cases), then your top speed is limited b...
by hias9
Aug 10 2021 8:20am
Forum: EBike Technical
Topic: Sealing Phase Wires Exit
Replies: 3
Views: 199

Sealing Phase Wires Exit

I plan to upgrade from 4mm2 to 6mm2 phase wires through the axle. Outside the motor I already use 8mm2 phase wires. There is enough space to put three 6mm2 and six thin (maybe 0.2mm2) PTFE insulated wires through the channel in the axle. Because I am using ferrofluid, I want to seal the wire exit. W...
by hias9
Aug 04 2021 9:45pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

The day before (the motor also was above 140 degrees that day), a few hours after riding, there was no 20% increase in no-load speed, but in no load consumption (ampere and watts). No-load speed was unchanged. Even now no load speed is only 1% higher, but consumption while the motor is spinning no l...
by hias9
Aug 04 2021 7:01pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

Please check the first post. I measured with a milliohmmeter and phase-to-phase resistance was equal over the three combinations. Motor still works fine, but has higher drag + vibrations at some speeds. Comlpete demagnetization happens way over 300 degrees celsius for neodymium magnets as far as I k...
by hias9
Aug 04 2021 6:29pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

I will open it when I am back in about 2 weeks. The last time I had opened it (after it was around 135 degrees for a few minutes), the yellow insulation plate got soft, some bamboo sticks got loose (removed them all) and windings (claimed to be rated 180, but manufacturer corrected to 130 degrees la...
by hias9
Aug 04 2021 6:00pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

It's a 24'' wheel and it can take about 5-6kw continous (at higher speeds) with Statorade + cooling fins. 20kw+ peaks are only for a few seconds when accelerating full throttle at highest level and motor heats up quickly of course. As already mentioned, 2 years no problem with 120 degrees celsius li...
by hias9
Aug 04 2021 4:04pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

Very interesting. Yes, they have to be magnetically separated and a short would increase core losses. But I never heard of a hubmotor where this has happened. Does anybody know at which temperatures this starts to happen? I would expect this to happen only at much higher temperatures than the 150 de...
by hias9
Aug 04 2021 2:21pm
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

Yep, exactly. This motor is meant to test the limits of the components, to see which components need to be replaced if one would want to run it up to a higher temperature.
It worked fine before for 2 years with a maximum limit of 120 degrees celsius at the windings.
by hias9
Aug 04 2021 11:43am
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

With increasing temperature, efficiency gets worse, but the motor case + cooling fins can dissipate more heat when hotter. If you allow a higher continous operating temperature, you can push more power through it continously (while efficiency suffers however). If you allow a higher peak temperature,...
by hias9
Aug 04 2021 10:18am
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

For stock DD hub motors (without windings, magnets, hall sensors, insulation upgraded), a hard limit of 120 degrees celsius should be fine based on my experience. Above 130 degrees celsius problems start. On a geared hub I already had nylon gears destroyed at 90 degrees celsius motor temperature. If...
by hias9
Aug 04 2021 9:59am
Forum: EBike Technical
Topic: Increased drag after DD motor was close to burn
Replies: 34
Views: 747

Re: Increased drag after DD motor was close to burn

With the wheel up in the air, after accelerating to no-load speed it usually took maybe about 20 seconds until the wheel came to a stop.
Now it only takes about 5 seconds.