Endless Sphere

We have peek and ULTEM too but I think nylon is best since it will give some before it fractures since it’s not as brittle On the plus side I found bearing CSK30PP is the same sprag clutch but also has an external key way which we can use to lock into the plastic gear !!! I found an old protective ...

Interesting to look at this regarding 3D printer material.

I did draw the main gear from the picture. It must be OK. But just to be sure can you print at scale 1X and check with the main gear in place. Cut de 62mm bearing hole and mount the sheet over the main gear. Or remove the main gear and drop it on the printed gear drawing. If all look OK I will resen...

This place has some really good picture https://www.emotoer.com/tsdz-main-gear/ I have also contacted the supplier to see if they can share anything but hope to pull mine apart on the weekend JB Yes these are fine pictures. Knowing the one-way bearing diameter (62mm exactly) I will try to do the jo...

Wapous, not sure I understand Are you saying you may have the number of teeth wrong and the shape of the teeth may be incorrect and not sized properly ? There is a big difference between preparing technical drawings for production and machining and preparing drawings to present a design for illustr...

Cool idea!! Wapous, maybe you could share that both parts (part with teeth and the part of gear) and STEP files, so jbalat can first 3D print both to test before send to machining the metal gear. Even maybe someone can first 3D print in PLA just to have a feeling how it will work!! As already menti...

Hi Wapous, I have the straight cut teeth on my large gear, I was thinking whether we could make an outer gear ring in nylon and machine down the metal gear and drill and tap some holes so that we can screw on the nylon part. We have industrial 3D printers at work so I could print one. If you could ...

casainho wrote: ↑

Feb 13 2021 2:59am

That is a lot of kms. I am curious about the type of bicycle you use? Road bike?

20,000 km is the total for both. Means 5000km on each bike per year.
Bike are Specialized. Hybrid.

Since we modified our bikes with the TSDZ2 engine two years ago my wife and I have ridden over 20,000 km. We travel on roads and rarely do we go off-road. For us, the minimum power is sufficient. So our average range is 90 km with a 48volts / 14ah battery. We are completely satisfied with our modifi...

Hi Wapous, I have the straight cut teeth on my large gear, I was thinking whether we could make an outer gear ring in nylon and machine down the metal gear and drill and tap some holes so that we can screw on the nylon part. We have industrial 3D printers at work so I could print one. If you could ...

As it is impossible to modify the diameter of the driving gear and that of the driven gear, I stop this development. I include the technical drawing that the suppliers received. Thanks!! Well that sorts that idea, pity as a quiet motor would be great. Thanks for doing all the enquiries Wapous. Than...

I have received information from a supplier regarding the replacement of the helical gear mechanism by a belt drive. The belt system would not work as they say a ratio exceeding 4: 1 is not recommended. Let's not forget that the system ratio I presented is 6: 1. As it is impossible to modify the dia...

Can you do it all by yourself? design the gears, machine them, install and test? this would be great, you would me able to move quick!! and simplify, do not try to make everything perfect / follow the 4 specifications you wrote in the first iteration. [/quote] This design shown here is just a conce...

Subject: Study for the replacement of the gear mechanism by a belt drive mechanism. Specifications: 1- A mechanism easy to implement without major modifications. 2- The mechanical efficiency (torque) must be similar. 3- The noise of the mechanism must be less being the desired goal. 4- Establish the...

It is easy to understand the problem. I don't know if we can reverse the direction of rotation of the 3-phase motor. The one-way bearing of the blue gear should be reversed.
So my question is: Can we reverse the rotation of the 3 phases motor?

The timing gear (gold color) is an existing model with around 16 teeth. To me, it is obvious that the main gear needs to be replaced with a new machined part. I will study this in more depth this month. Ultimately this modification would be similar to the Bose motor drive mechanism. This modificatio...

TSDZ2 motion study video
Hope I did it easier to understand!


https://youtu.be/EsMlBj6ogVQ

Just for references! It is your design? If so, can you share the source files? because I am pretty sure they can be very useful for others. And I wish some mechanical guy could improve the motor by reducing the noise - I think the noise comes from the gears, maybe from the main gear and the pinion ...

In turbo mode it's seems to be spinning faster which reduces the perception of a drag. Exactly, its very easy to feel in lower assist levels BTW thank you Wapous for the schematics.. It would be great to do a video/animation to get a better visualisation of how it works to see if there are any easy...

Just for references! It is your design? If so, can you share the source files? because I am pretty sure they can be very useful for others. And I wish some mechanical guy could improve the motor by reducing the noise - I think the noise comes from the gears, maybe from the main gear and the pinion ...

Just for references!

Waynemarlow wrote: ↑

Jan 27 2021 11:01am

Just to be different, you can fit the TSDZ2 into the Bafang M500 / M600 frames.

Very nice job.

I have this problem too, which is posted unanswered in the "E-Bike Technical" section. Anyone have any ideas? Yes I have the exact same thing... Didn't find what it is though....did you get any wiser? Nope. I suspect something is rubbing where I can't see it. Haven't found it yet Same her...

I've replaced all the bearings with proper german ones except for the blue gear for I could not get them out without damaging the blue gear...is there any way to get them out without using a press? Thanks for any advice 🙂 [/quote] This is the way I do replace the blue gear clutch bearing. I am tryin...

For many of us, the time has come for a good cleaning and refurbishment of our TSDZ2. This often involves the replacement of different bearings.
Hope this might help you.