PaulD
1 kW
I had the opportunity to open up a Fazua Ride 60 motor to investigate a motor noise issue. Much like the EP8 motor I worked on in a previous thread, this was not easy. These OE motors are not designed to be simple to work on. I designed 4 custom tools just to open the case and remove the spindle assembly. Unfortunately, I can't see any way to get the planetary gearbox and motor out of the case without excessive force. The customer got a warranty replacement, so this motor doesn't need to be returned, so this is more of an educational exercise.
One of the problems with these OE drives, is that they are very difficult to test without the right diagnostics tools from the manufacturer. I can't even test anything without a complete bike hooked up to it with the OE battery, display, etc.
Initially, I thought it would make sense to remove the spindle assembly first (EDIT: don't try to remove the spindle before the motor side of the case. The torque sensor blocks removal of the spindle, and will get damaged (see cracked die casting below))
This is the where the controller goes, and the phase connectors mate. The pigtail goes to the torque/cadence sensor. It looks like it uses a magnetic encoder.
This is the controller board. Very compact.
Backside of the torque sensor board. The red boards I think are wireless transmitters/receivers for the torque sensor.
Otherside:
These are the custom tools. The small one is a custom socket to remove some unique pins that hold the 2 parts of the case together. I had to get it 3D printed in steel. Let me know if anyone wants to borrow it, or have the CAD files. This also shows the helical bevel gears... No sign of wear, but i think the mileage is pretty low on this drive.
Just making sure the bearings and gears don't sound bad by spinning the motor up with an external controller. No obvious bad sounds. The grinfineon controller I'm using struggles once the ERPMs get too high, so I can't spin it any faster at the moment.
Attempting the excessive force method for removing the motor/gearbox. No dice.
One of the problems with these OE drives, is that they are very difficult to test without the right diagnostics tools from the manufacturer. I can't even test anything without a complete bike hooked up to it with the OE battery, display, etc.
Initially, I thought it would make sense to remove the spindle assembly first (EDIT: don't try to remove the spindle before the motor side of the case. The torque sensor blocks removal of the spindle, and will get damaged (see cracked die casting below))
This is the where the controller goes, and the phase connectors mate. The pigtail goes to the torque/cadence sensor. It looks like it uses a magnetic encoder.
This is the controller board. Very compact.
Backside of the torque sensor board. The red boards I think are wireless transmitters/receivers for the torque sensor.
Otherside:
These are the custom tools. The small one is a custom socket to remove some unique pins that hold the 2 parts of the case together. I had to get it 3D printed in steel. Let me know if anyone wants to borrow it, or have the CAD files. This also shows the helical bevel gears... No sign of wear, but i think the mileage is pretty low on this drive.
Just making sure the bearings and gears don't sound bad by spinning the motor up with an external controller. No obvious bad sounds. The grinfineon controller I'm using struggles once the ERPMs get too high, so I can't spin it any faster at the moment.
Attempting the excessive force method for removing the motor/gearbox. No dice.
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