Bafang G062.1000.DC mods to run peak 6000w +regen

[TuomasK]

Bafang G062.1000.DC with little mods can take quite alot of Power indeed.
I've been running this motor step wise higher and higher in power. Motor casing is vented, wiring beefier, solid cluth and real time temp logging installed. After couple of years of usage first set of gears still going strong. I'm using generous amount of SHC100 grease on gears. After some time running 60v 64A peak the gluing of magnets failed. After carefully gluing them back with Permabond ET5441 (with heat cure) the motor is better than new. Now after these fixes I modded the controller (with some risk of course) to run peak 114A (few seconds) leveling to 80A.
Welding the clutch solid enables regen to be used which is nice besides clutch being stronger it saves brake pads
Temp logging device is nice and shows both real time temp with phone app and enables exporting to Excel. Recorded peak winding temp ~120°C, more typical peak temp ~100-105°C.

 

[CandyAloha]

Thats very impressive! I always wanted to see these motors pushed.

 

[chuyskywalker]

That's pretty wild.

 

[pullin-gs]

No mods with my g062 motor. Running stock at 1500w-ish for 2 hours sustained mostly on forest roads and trails.
I toredown motor last month when I had 2200 miles to inspect. It looked like new.
I am considering changing out stock phase wires and uppeimg my controller amps to 50a (currently 35a max)
Thoughts?

 

[SlowCo]

Bafang G062.1000.DC with little mods can take quite alot of Power indeed.

Great to read it can take that much power. What controller are you using?

 

[TuomasK]

Bafang G062.1000.DC with little mods can take quite alot of Power indeed.

Great to read it can take that much power. What controller are you using?

KT based custom version. Was originally 64A. Now 114A couple of seconds then drops to 80A.

 

[Altema22]

I've been trying to purchase Permabond ET5441 in the US, but cannot find it. A search on Amazon gives me hundreds of other products, but not that one. Do you know a source? I have six motors with magnets I need to glue.

 

[TuomasK]

I've been trying to purchase Permabond ET5441 in the US, but cannot find it. A search on Amazon gives me hundreds of other products, but not that one. Do you know a source? I have six motors with magnets I need to glue.

Have you tried asking Grin tech (ebikes.ca)?

 

[TuomasK]

Some dyno results on mies G062. Slight user caused throttle slip at higher rpm but overall good result and matches motor simulator nicely. No big issue with saturation detected. Battery current 90A, phase current 190-200A. Still torque approx 190Nm. Battery at 90% SOC. Due to extreme cold weather (~0°F) the battery was colder than optimal (~40°F). Summer time max battery output measured 6000w.

 

[Papa]

Some dyno results on mies G062. Slight user caused throttle slip at higher rpm but overall good result and matches motor simulator nicely. No big issue with saturation detected. Battery current 90A, phase current 190-200A. Still torque approx 190Nm. Battery at 90% SOC. Due to extreme cold weather (~0°F) the battery was colder than optimal (~40°F). Summer time max battery output measured 6000w.

FYI... Not all G062 motors posses identical guts, I suspect many are cheap copies.

 

[TuomasK]

View attachment 346147

FYI... Not all G062 motors posses identical guts, I suspect many are cheap copies.

This is modded motor so not identical to most G062s.

 

[scianiac]

I'm just finishing up a bike with two of these motors now and am playing with the power levels and future planning, currently running 68PA on each now still with stock but short phase wires and MT60 connectors and no other mods besides better greasing. The real thing I'm wondering is at what point will the Nylon gears fail from torque vs heat. I've read around 75PA you start to need bigger phase wires, steel gears, replace the clutch key with a stronger one and of course cooling mods for continuous power.

Do you have an idea how much louder the steel gears are? I suppose they are even louder with the vented case although I think I would try an oil filled case instead of venting since with my use massive amounts of snow ingestion would occur with a vented case.

 

[TuomasK]

I'm just finishing up a bike with two of these motors now and am playing with the power levels and future planning, currently running 68PA on each now still with stock but short phase wires and MT60 connectors and no other mods besides better greasing. The real thing I'm wondering is at what point will the Nylon gears fail from torque vs heat. I've read around 75PA you start to need bigger phase wires, steel gears, replace the clutch key with a stronger one and of course cooling mods for continuous power.

Do you have an idea how much louder the steel gears are? I suppose they are even louder with the vented case although I think I would try an oil filled case instead of venting since with my use massive amounts of snow ingestion would occur with a vented case.

I have had 2 failures on the way. First rotor magnets came loose. Now they are way better attached. Seconds time little improved phase wiring failed. Now 8awg and problem solved.
I still use stock nylon gears but avoid wheelies etc. Venting and good grease (SHC100) keeps gears cool. Heat softens Nylon. Liquid cooling removes some heat from windings. Clutch is welded but still stock key. I could use regen but avoid because of additional stress to axle, key and gears.
Winding temp monitoring is even more usefull with geared motors.
Stock phase wiring may be ok for <100 phase amps peak. Of course depends on usage profile etc.
I havent have any issues with snow up to this point. Not riding in deep snow though.

 

[scianiac]

Very useful information, I was wondering how much the gear failures were due to heat vs overstress as I intend to keep the heat down. And deep snow doesn't do much shock loading so good for gears. I do plan on replacing the phase wires and installing a temp sensor, why they include the stupid wheel speed sensor and not a temp sensor in it's place I don't know, like if you want the wheel speed just use the hall sensors an divide.

I did re-grease with SHC100 but I mixed about 10% teflon powder into it as well as the research I've seen seem to indicate that Nylon on steel gearing systems respond very well to teflon thickened PAO grease, providing the good efficiency at both low and high loadings. I believe SHC is a lithium complex PAO grease but stupid Mobil doesn't even tell you what the base oil is so I'm not totally sure. Honestly I don't like the SHC100, not because it isn't a good grease (ok well I wish it separated less when sitting) but because I don't like Mobil.

As for cooling if I need it I'm hoping the oil bath, cold case temps and thermal throttling will be enough. So far we haven't had a ton of snow to try it out much, the real deep stuff it just requires a crazy amount of power to make any progress but does do it, we've got some shallower snow now and it should blast through this.

 

[awb1985]

Some dyno results on mies G062. Slight user caused throttle slip at higher rpm but overall good result and matches motor simulator nicely. No big issue with saturation detected. Battery current 90A, phase current 190-200A. Still torque approx 190Nm. Battery at 90% SOC. Due to extreme cold weather (~0°F) the battery was colder than optimal (~40°F). Summer time max battery output measured 6000w.

Hello I'm doing a similar build on my Ariel grizzley. 60v fardriver 72300 one for each motor. I have a question regarding pole pairs. Is it 20 magnets 10 pole pairs?

 

[TuomasK]

Hello I'm doing a similar build on my Ariel grizzley. 60v fardriver 72300 one for each motor. I have a question regarding pole pairs. Is it 20 magnets 10 pole pairs?

Yes

 

[neptronix]

Got video? would love to hear/see, amazing how overbuilt these motors are

 

[TuomasK]

Got video? would love to hear/see, amazing how overbuilt these motors are