VESC based INNOTRACE motor controller for Bafang M560/510

[TPEHAK]

During last months I got some private messages with inquires regarding purchasing those controllers for Bafang motors we reversed and designed. If you do not want to order the controller fabricated from JLCPCB for instance, I recommend you to contact VESC Labs, maybe they want to make and sell these controllers since there is such demand. We do not care how they want to brand it and represent it or modify it, they can even call it VESC Labs again, but if they want to start making money like there is no time tomorrow I am sure they will happily manage fabricating and selling these controllers for you guys, especially Benjamin Vedder is aware of these controllers.

Alternatively you can try to contact LUNA, or Marcos from Paltatech, or maybe Dynamesys. While they were net very helpful when we asked their help with the controllers, ultimately they want to make money too, so maybe it will spark their interest so they can manage the controllers fabrication for you so you can purchase it from them.

Hell, you can even try to contact Krasnodar from EXFORCE if none of the above works, maybe he is willing to help and will make it happens. I do not know if he is happy with selling his new controllers, we still have not seen a single one in the wild, but if he is not, he might agree to help the ebike community this way and sell our INNOTRACE controllers.

At the end of the day these controllers are open source and anyone can make them, so you can send your inquirers to anyone who makes the controllers. You can even ask Flipsky or MakerBase and point them to our threads in this forum.

 

[Wowo]

I've already done this =). I haven't had the opportunity to fully test it yet in winter.

If your controller doesn't throw an error when the clutch is locked, you can firmly lock the gears. The original controller, however, throws an error about excess current when pedaling, likely due to the generation.

→ Have you done the test HFL1626

 

[TPEHAK]

I think we need one more attempt with INA. I purchased a new M560 clutch and a new INA. This time there will be no extra lubrication and the clutch race will be fresh with no wear.

Already extracted the original one way bearing











By the way, you can see the Germany made INA overrun clutch has thinner shell and larger rollers for bearings and for the the clutch than the Bafang overrun clutch. Let's hope it will make the trick.

 

[TPEHAK]

The INA has been installed.

 

[TPEHAK]

If you want to replace the overrun clutch you need this tool

Amazon.com

You also need a 9/16" socket or similar with the outside diameter slightly less than 20mm to push the overrun clutch.

You also need the adapters. The adapters are 3D printed parts, I used PLA. You can download the CAD models here and you might need to adjust the adapters sizes depending on your 3D printer tolerances and the tools you have

Onshape

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[TPEHAK]

The clutch gear I obtained from AliExpress has no markings on it while the M560RS gar has markings. I also noticed the the thin washer between the bearing and the overrun clutch is metal on the AliExpress gears while this thing is plastic on the Bafang M560RS. Let's hope this is the correct part and not a counterfeit.

 

[TPEHAK]

It turned out the clutch gears are different. They have different teeth angle. How do I know which one to purchase?



I does not sit parallel on the M560RSs main gear.



I also found Green Bike kit offer M560 and M510 main gear and freewheel gears as separate options.

Bafang M560 M510 main steel gear for replacement-Greenbikekit.com BBS, ebike batteries, Bafang M620, Bafang M600, Bafang M500, Bafang M510, KT controller with display-GreenBikeKit.com

Bafang M560 M510 main steel gear for replacement

www.greenbikekit.com

Bafang M600 M560 M510 M500 freewheel gear-Greenbikekit.com BBS, ebike batteries, Bafang M620, Bafang M600, Bafang M500, Bafang M510, KT controller with display-GreenBikeKit.com

Bafang M600 M500 M510 M560 freewheel gear for replacement.

www.greenbikekit.com

So it looks like I purchased M510 second gear instead of M560. I was thinking all those gears are the same.

 

[TPEHAK]

The weird thing is I can not find the one way gear for Bafang M560 anywhere. All the gears I found are for M510. Green Bike Kit says it is out of stock. Welp, I guess I need to try to swap the main gear to M510 and hope it will fit M560RS. It looks like the M510 main gear teeth angle is steeper so the lateral force is going to be bigger than on M560 gears. Let's hope M510 gears will not destroy themself.

 

[TPEHAK]

Finally got rid of the foam and made a proper speed sensor bracket. If you have a Kunlun frame and want to use it with this controller you can 3D print this one optimized for FDM 3D printing.

Onshape

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[TPEHAK]

The M510 main gear has arrived and has different teeth angle comparing with the M560RS main gear but the rest looks similar. Will see if it fits M560RS motor with M510 clutch gears.





Buy the way Green Bike Kit now has M560 clutch gear in stock but for some reason it is more expensive than M510 clutch gear. If M510 clutch gear will work without issues it is certainly more appealing option.

 

[TPEHAK]

Installed M510 main gear with M510 clutch gear with INA clutch into the M560RS motor and it works without issues so far. Will see for how long new clutch gear with new INA will last.

You can see the M510 and the M560RS main gear teeth angles are different