Search found 114 matches

by sysrq
Oct 14 2019 6:19am
Forum: E-Bike Non-hub Motor Drives
Topic: TSDZ2 Sprag clutch
Replies: 4
Views: 286

Re: TSDZ2 Sprag clutch

It has been said in one German forum that this is a very brave engineering from a company like Tongsheng, since normally there should be a bearing next to the sprag clutch to reduce the play.
by sysrq
Oct 01 2019 8:56pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

So I just went for a relatively short 8 or so mile ride, mostly flat, but there is a pretty long hill coming back. I have the custom firmware and keep my power max at 450. Going up the hill, I did have the PAS on the highest setting. I noticed when I got back the motor was warm/borderline hot to th...
by sysrq
Oct 01 2019 7:44pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

So I just went for a relatively short 8 or so mile ride, mostly flat, but there is a pretty long hill coming back. I have the custom firmware and keep my power max at 450. Going up the hill, I did have the PAS on the highest setting. I noticed when I got back the motor was warm/borderline hot to th...
by sysrq
Oct 01 2019 5:10pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

What about the price of the Loctite 660 and being able to remove the parts again. Seems like the price doesn't outweight the benefit in this case. Not sure about angular and radial misalignment. The loctite 660 is cheep (very small tube, $8USD -Amazon). I figure I will rig up a puller (with an extr...
by sysrq
Sep 23 2019 4:34pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

Almost seems like the play is intentional for ease of installation. Quite weird when knowing that helical gears normally work with conical roller bearings to take the side loads. Mine suddenly started to make perriodic rough grinding noise when completely unloaded on to of the usual gear mesh sound...
by sysrq
Sep 23 2019 10:19am
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

Hi, I replaced the sprag cluch on my engine but it turns out the play is between the inner race of the sprag and the axle. The problem is that the fit of the sprag on axle is loose and the presence of the key makes it even looser. I'm working on a key that can be expanded to fix the sprag better to...
by sysrq
Sep 23 2019 10:02am
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

Hi there, I am quite interested in this TSDZ2 and I have a few questions. I have a Giant electric bike (Explore E+), 36V/250W, max 25kmph It's powerful and great to go uphill but once on the flat or downhill it's heavy like a tank and I don't have much fun riding it. I am planing to install an elec...
by sysrq
Sep 23 2019 9:42am
Forum: E-Bike Non-hub Motor Drives
Topic: Hardware temperature control tsdz2
Replies: 54
Views: 2441

Re: Hardware temperature control tsdz2

... I don't have a temperature sensor installed since normally it should be next to the stator windings. .............. Now waiting for non-adthesive 1.5mm thermal pads so that there aren't any possible air gaps compared to the ones which were made thinner. OK, that explains problably the reason fo...
by sysrq
Sep 18 2019 10:41pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

Hi, I replaced the sprag cluch on my engine but it turns out the play is between the inner race of the sprag and the axle. The problem is that the fit of the sprag on axle is loose and the presence of the key makes it even looser. I'm working on a key that can be expanded to fix the sprag better to...
by sysrq
Sep 18 2019 10:27pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: Dual chain rings

I finally got my dual chainring configured. The chain alignment is not as good as I would like, but I think it will work. I trimmed (thinned) both the inside of the spider and the outside of large ring to reduce the amount of offset. Then I added 3 thin SS washers to offset the spider. I then put s...
by sysrq
Sep 18 2019 10:09pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

This is a step in the Right Direction, at least 750 watts, throttle option, and double chainring option, Watts is volts times amps, so the "15A 48v" system is already 720, and the 18A version crosses the line with 864. Given that a "48v" battery is typically charged to 54.5v or thereabouts, and, at...
by sysrq
Sep 15 2019 9:05am
Forum: E-Bike Non-hub Motor Drives
Topic: Hardware temperature control tsdz2
Replies: 54
Views: 2441

Re: Hardware temperature control tsdz2

The ring/clamp is handmade. Good work, I hope it is possible to publice soon some temperature measurements of the motor too. I don't have a temperature sensor installed since normally it should be next to the stator windings. Could use standalone one but don't want any more clutter to check all the...
by sysrq
Sep 15 2019 4:51am
Forum: E-Bike Non-hub Motor Drives
Topic: Hardware temperature control tsdz2
Replies: 54
Views: 2441

Re: Hardware temperature control tsdz2

......... Right okay, made some pictures of not long ago. Turns out the thermal pad on the top should be about 1-1.5mm instead of 3mm, so had cut them thinner despite the resulting uneven surface. 12W/m.K tacky soft thermal pads on on laminated core, stacked adhesive rubbery 6W/m.k thermal pads on ...
by sysrq
Sep 14 2019 6:46pm
Forum: E-Bike Non-hub Motor Drives
Topic: Hardware temperature control tsdz2
Replies: 54
Views: 2441

Re: Hardware temperature control tsdz2

Tried out some crude experiment ........ Nice expreriment you did :) You have some pictures too? What is the size/thickness/mass of all these materials you had measured? Do I understand you well that you measured: copperfoil attached on both sides of pyrolytic layer Pure copper Pure aluminium Right...
by sysrq
Sep 14 2019 8:27am
Forum: E-Bike Non-hub Motor Drives
Topic: Hardware temperature control tsdz2
Replies: 54
Views: 2441

Re: Hardware temperature control tsdz2

Tried out some crude experiment with homemade 20x55mm copper foil strips containing encapsulated/laminated 1850 W/m.K pyrolytic graphite for better z axis thermal conductivity attached by rubber bands to an aluminium can 70mm in diameter and 40mm in height and compared the temperature rise while pou...
by sysrq
Sep 10 2019 12:18pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

Has anybody tried to reinforce the plastic gear cover from the inside while shaving of the corresponding circular pattern parallel of the protruding 110BCD screws. That might not help cause the cover extends too much over the pinion gear making it impossible to the chainring in parallel to the plas...
by sysrq
Sep 09 2019 11:36am
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

New and improved :D I changed out my modified inner chainring with the stock steel offset one, with an original spider and my trimmed 53 tooth chainring. I took off about 1.5mm, (see photo) and had to add 1 thin washer between the spider and drive hub. This change eliminated 2 offset washers, and d...
by sysrq
Sep 08 2019 9:24am
Forum: E-Bike Non-hub Motor Drives
Topic: Hardware temperature control tsdz2
Replies: 54
Views: 2441

Re: Hardware temperature control tsdz2

............... So there might be insufficient heat transfer capacity below 1mm thickness? https://www.electronicdesign.com/circuit-protection/pyrolytic-graphite-sheet-evolves-meet-tough-thermal-demands Cooling only front part of the motor itself could create internal hotspots. We are not talking a...
by sysrq
Sep 08 2019 5:32am
Forum: E-Bike Non-hub Motor Drives
Topic: Hardware temperature control tsdz2
Replies: 54
Views: 2441

Re: Hardware temperature control tsdz2

......... EYGA091202A was no more expensive than a copper plate. ......... The sheets I found are only 17┬Ám, meaning you need 60 layers to get a 1mm. :? I think the cheapest way is to use metal for reasonable thermal conductivity Massive, braided, pressed sponge or pressed mesh, where (massive) cop...
by sysrq
Sep 07 2019 6:12pm
Forum: E-Bike Non-hub Motor Drives
Topic: Hardware temperature control tsdz2
Replies: 54
Views: 2441

Re: Hardware temperature control tsdz2

5 or 6 adhesive pyrolytic graphite sheet strips around the motor and stacked 3mm thermal pads on top of the motor end cap pressing against the cover lined with adhesive pyrolytic graphite sheet to spread the heat better, since the covev looks lika a casted aluminium alloy which a are known to for th...
by sysrq
Sep 06 2019 10:16am
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

Here is a price sheet for the Panasonic TIM pads. ............... Lower # is better. You can see that a thinner pad has less resistance, and lower cost. If used inside a copper ring to tranfer heat from all the way around the motor....... I understand your arguments for this choice. Copper and a th...
by sysrq
Sep 05 2019 2:37pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

Here is a price sheet for the Panasonic TIM pads. ............... Lower # is better. You can see that a thinner pad has less resistance, and lower cost. If used inside a copper ring to tranfer heat from all the way around the motor....... I understand your arguments for this choice. Copper and a th...
by sysrq
Sep 04 2019 2:48pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

Good info thank you. So seems like the laminated core area is the preferable place to remove heat from. I like the idea of building up that area and wrapping it with copper bar and having that copper bar go through the outer casing. The brainstorming continues..... Well yeah, without drawings there...
by sysrq
Sep 04 2019 1:01pm
Forum: E-Bike Non-hub Motor Drives
Topic: New "TSDZ2 Torque Sensor Central Motor"
Replies: 5944
Views: 497612

Re: New "TSDZ2 Torque Sensor Central Motor"

I'm looking to make a heat removal mod. I have seen a a few heat transfer mods utilizing the end of the motor where there is wiring and a large air space. Has anyone considered using thermal paste on the other side of the motor? It seems like there is a nice flat metal to metal interface where ther...