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  1. S

    Bafang BBSHD Rotor...

    Also issues with delamination, stack deformation resulting in uneven air gap between stator and rotor and cling film sticking out left behind between some of the laminations. This means you always have to buy them in person in order to find the best one which is impossible.
  2. S

    Scratched IPM motor laminations

    Some people were recommending using Loctite 638 for magnet retention on Surron motors but apparently it's intended for cylindrical press fit applications only. Also tried unopened JB Weld Plastic Bonder but it's not hardening anymore due to short shelf life. Industrial grade UV cure structural...
  3. S

    Scratched IPM motor laminations

    Turns out loctite 638 isn't adhering to laminations after 18 hours in bench vice.
  4. S

    Scratched IPM motor laminations

    Flat type IPM rotor topology has the worst robustness and easiest manufacturing speed suitable for high profits according to this paper. https://www.mdpi.com/1996-1073/16/9/3635 Adopting V type topology would require different stator configuration.
  5. S

    Scratched IPM motor laminations

    It might cause rotor imbalance depending on thickness required. Will it adhere to insulated coatings of laminations?
  6. S

    Scratched IPM motor laminations

    I could use loctite 638 which is rated at 180°C. Seems like the pressure required to hold this this delamination together is higher than for other rotors.
  7. S

    Scratched IPM motor laminations

    If segmentation of magnets is used in other rotors then shorted rotor laminations can increase eddy currents in general. According to some of the posts on endless-sphere sphere and according to Google AI and ChatGPT shorted rotor laminations can cause localized heating.
  8. S

    Scratched IPM motor laminations

    Turns out in some of the BBSHD IPM rotors laminations have uneven radial size on one side resulting in chance of delamination due to removal or insertion and possible imbalance which might increase vibration. Third example has multiple protruding laminations on one side. Looks like this one...
  9. S

    DIY BAFANG builds with torque sensor? based on 2024 workbook

    Are there any disadvantages of having no thrust bearing in M635 compared to BBSHD?
  10. S

    Scratched IPM motor laminations

    Got a spare rotor and stator to practice pressing on new bearing in order to prepare for unexpected issues with arbor press and compare the symetry of windings with inductance meter and four wire miliohm meter. Turns out new rotor has even worse delamination despite fallowing the most popular...
  11. S

    Scratched IPM motor laminations

    Does delamination resulting in 0.2-0.3mm gap and some superficial scratches justify replacement of IPM rotor? Google AI says possible shorts caused by scratches will increase eddy currents despite the fact that all of the laminations are shorted together by magnets and axle according to...
  12. S

    Bits of metal under 16003 bearing and cling film under 16001 left in bearing bores by factory in BBSHD.

    Might be the reason for uneven pinion gear axle drag and notchy 16003 bearing and uneven secondary gear wear pattern with possibility of micropitting. Will see if FAG bearing will last longer.
  13. S

    BBSHD scratched axle

    The old seal feels tight around the axle. I have Shell Gadus s5 v100. Also found metal shavings below the 628 motor axle bearing and some cling film left behind by Bafang factory below the 16001 nylon gear axle bearing (might have caused some axle binding issues seen from the start). Edit. No...
  14. S

    BBSHD scratched axle

    The small white particles are just dust. Its hard to find the scratch even in person. It's not upside down. Old needle bearing feels gritty and I can see some metal shavings inside. Despite that axle is smooth overall without reduced diameter due to wear.
  15. S

    BBSHD scratched axle

    Does shallow 0.1 mm scratch which doesn't catch on fingernail justifies axle replacement? It's close to the left side below the bright reflection. Chatgtp says it will polish itself out by skf bearing in this case especially with extreme pressure synthetic grease. Protective covers or tapes...
  16. S

    Gustavo chainring for Bafang mid drives

    There are still only two videos available on how to install it and both recommend hammering outer edge of the bearing resulting in damage. The bearing feels crunchy after 1000km despite using rubber mallet on a medium thickness carpet. Might result in gear misalignment eventually when play...
  17. S

    BBS-FW: Open Source Firmware for BBSHD/BBS02 Controller

    Ability to switch between different throttle profiles on display (might be possible in phone app only) might be another possibility to add to the existing firmware. Chainbreaker app is probably not talked about due to inherent absence of simple PAS level adjustment at the handlebars.
  18. S

    BBS-FW: Open Source Firmware for BBSHD/BBS02 Controller

    According to chatgtp quadratic throttle can reduce smoothness in the middle zone. Since I'm using pedals for slow speed manoeuvring then I may not need quadratic throttle.
  19. S

    BBS-FW: Open Source Firmware for BBSHD/BBS02 Controller

    Using 1% start current and 1A per second in global settings there is no chain slamming as long as throttle is applied slowly. With origin firmware throttle response was a lot more unpredictable. As far as I understand judging from various contradictory replies on github quadratic throttle will...
  20. S

    BBS-FW: Open Source Firmware for BBSHD/BBS02 Controller

    Are there any reports of unexpected motor activation when using USB port on DPC-18 display for charging? Luckily PAS level ones had only 5% max current and 5% speed so the BBSHD motor was easily stalled. It could be a part of first original problem which still persists (motor gets activated...
  21. S

    Controller an battery combinations

    I was referring to cooling of a single cell in free air. Rated continuous current of the battery is 31A. Maximum controller current is 28A. Some say continous current should be twice as high as battery current. This means that only 15A controllers can be used with 35e 14s6p 31A (40A burst)...
  22. S

    Controller an battery combinations

    Should continuous battery current match the controller maximum current or is enough that rated battery burst current is higher? So far with current setup maximum load on 35E cells rated for 8 Amp continuous load in free air only is 4.66A.
  23. S

    BBSHD starts motor in PAS level 1 when charging phone from USB port

    Are there any similar cases being reported. So far haven’t stumbled upon anything like this in forums. Bafang keeps surprising. Previous issue: (throttle active for 1 second in PAS level 0).
  24. S

    Gear shift indicator solutions

    Already mounted two reed switches on deraileur using b-screw and special plastic bracket for the magnet. This shows three gears only first led on, two led's on and second led on. The cadence can change depending on different fatigue levels. There is a plan connecting reed switches to existing...
  25. S

    Gear shift indicator solutions

    It's hard to know if it's the right gear for the motor by feel (not too low not too high) if you want to stay in one gear in full throttle in slightly changing conditions.
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