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General Discussions / Re: ... Steering Headset and Front Wheel Motors ...

« Last post by Bikemad on February 28, 2024, 12:04:41 PM »

Hi Don,

As you have steel forks that are also fitted with a torque arm you don't need to worry, as the load on the headset is significantly greater from heavy braking forces applied to a conventional wheel than the torsional forces generated from a front mounted hubmotor under full power.

Forks that are able to be used with disc brakes would be the best option for a front mounted hubmotor as they are designed to withstand torsional forces at the lower end, whereas non-disc brake forks only had to withstand directional forces from the wheel's axle:

The biggest safety concern with a front mounted hubmotor is that the fork's dropouts are simply not designed to cope with any torsional loads from the axle in either direction when a conventional front wheel is used as the wheel bearings prevent this from happening.
However, with a hubmotor, the high torsional forces produced by the stator have to be transmitted through the axle, which is why torque arms should always be fitted when using a hubmotor to help withstand the bidirectional torsional forces produced by the axle within the dropouts while under power and during regenerative braking.

Alan

General Discussions / ... Steering Headset and Front Wheel Motors ...

« Last post by diverdon on February 28, 2024, 09:48:14 AM »

Hello , First I have got to say I'm so VERY Happy with my Magic Pie setup .. I ride 1 1/2 or 2 1/2 hours most every day and it has helped with my health a lot ...

Today I noticed a "knocking" noise when I went over bumps ... I ride slow 7-8 mph average .. Got home looked it over and it seems the steering head bearings came/got a little loose ..Tightened the nut 1/8th of an inch and the looseness is out now ...

Thing is ...Question is .. I posted in another forum looking for an exploded diagram of the steering head .... And someone came back with a comment that "I Better Change to a rear hub motor or the bike is going to "Grenade" ...

I didn't really appreciate that "help" ... Been riding this bike for over 3 years with no problems ...seems to me replacing the steering head bearings would just be a maintainece item ... I have done the rear hub 2 times already ..

Looking at the Bike in a picture I CAN see where a motor tugging on that front wheen could/might cause a problem ...

Can I get some opinions ? Please ? Seems there are thousands of front hub motors and I have never heard of steering head failures from them ...

Thank You for any help you can give ... Don

General Discussions / Re: Problem with the VEC200 controller

« Last post by Bikemad on February 26, 2024, 12:14:43 AM »

Quote from: KP on February 19, 2024, 12:17:17 PM

**So is there a recommended wiring standard? What size should I use for phase wire and hall wire?

The required gauge of the wires will depend upon several factors including:

The maximum current the wire has to carry.
The permitted voltage drop across the entire circuit.
The wire conductor material - copper or aluminium etc.
The total length of the wires in the circuit.

As the Hall Sensor wires only carry minimal current (milliamps) I would expect 16 awg to be more than adequate.

The VEC-200 controller has a maximum rated Phase current of 210 Amps, therefore I would have expected the Phase wires to be much thicker than 6mm² (10 awg).

According to the table on this webpage, 200 Amps would require a cross section area of 70mm² (2/0 awg) for a combined circuit length of up to 20 feet (6.1m).
However, as the Phase Wires are basically working as an AC circuit, and the rated Phase current is not a continuous current, I suspect that the wires may not need to be quite that large.

Unfortunately, as the wires you have used to extend the Phase wires are less than 10% of what appears to be the recommended cross sectional area, I suspect this (combined with the extended length of the Phase wires) may well be responsible for the 6 blink error you are experiencing.

Alan

General Discussions / Re: Problem with the VEC200 controller

« Last post by KP on February 19, 2024, 12:17:17 PM »

**So is there a recommended wiring standard? What size should I use for phase wire and hall wire?

General Discussions / Re: Problem with the VEC200 controller

« Last post by KP on February 19, 2024, 12:11:29 PM »

1.Does the fault occur under light or heavy load?
- Occurs when opening the control box. The motor has not been driven yet.

2. what length have the wires been extended?
- 6 sq.mm for phase wire and 16 awg for hall wire.
Have you used the same gauge wires (or preferably a thicker gauge) to extend the Phase Wires and Hall/Temperature Sensor wires?
- Use a phase wire of size 6 sqmm. Connect it to the phase wire attached to the motor by fixing a nut through the wire terminal. by not solder it. As for the hall sensor wire, solder it on both sides between the control box and the motor.

4. Have you ensured that decent soldered or crimped joins were made in the wires?
Connect and solder according to the golden motor diagram. Because the box flashes 6 times, it only happens sometimes. Because it can still run the motor.

5. Are you sure that none of the wires have inadvertently been transposed during the modification?
- I'm sure none of the wires were moved.

General Discussions / Re: Problem with the VEC200 controller

« Last post by Bikemad on February 19, 2024, 11:41:23 AM »

Quote from: KP on February 19, 2024, 04:45:48 AM

It happened after I lengthened the hall sensor wire and U V W wire. Does it have any effect?

Hi KP, after reading this additional information, I now have a few questions for you:

Does the fault occur under light or heavy load?
By what length have the wires been extended?
Have you used the same gauge wires (or preferably a thicker gauge) to extend the Phase Wires and Hall/Temperature Sensor wires?
Have you ensured that decent soldered or crimped joins were made in the wires?
Are you sure that none of the wires have inadvertently been transposed during the modification?

These vector controllers are designed specifically to work with certain motors, therefore lengthening the motor's Phase Wires may well have changed the overall resistance and/or inductance of the motor's stator windings, causing an incompatibility problem between controller and motor, especially if thinner wires have been used or poor connections were made.

It would probably have been much better to mount the controllers closer to the motors and then extend the Battery cables and control harness wiring, as this would not have affected the overall resistance or inductance of the stator windings.

Alan

General Discussions / Re: Problem with the VEC200 controller

« Last post by KP on February 19, 2024, 07:12:08 AM »

There are 2 sets of vector 200 controller and bldc motor 3kw. Both sets have 6 flashing warning lights: mosfet protection is the same, but both boxes will switch to Not at the same time
You have to turn the box on and off again and then it can be used again.