New member with seized 5kW motor

[Marcogi]

Hi, I’m a new member.
I have a Golden Motor 5kW BLDC motor that has mechanically seized after a few hours of use.
It’s completely blocked (cannot turn by hand). Bearings are OK, but I suspect a rotor–stator contact or magnet shift.
Can someone confirm the correct internal structure (axial flux) and provide disassembly instructions or photos?
Thanks!

[Bikemad]

Hi Marcogi andto the forum.

Unfortunately, I have never had my hands on a HPM5000 motor to dismantle, but I have attached a photo showing the inner components of the air cooled  HPM5000B motor which should give you a good indication of how the air cooled version will come apart.

However, after watching this video, the water cooled version looks like it may be a lot more involved to remove the rotor and stator assembly if the front and main body casing is all one piece.

It looks like you would have to somehow remove the cable glands and then feed all the wires inside the casing before being able to press out the rotor assembly from the front casing.

Just a thought, but if the threaded mounting bolt holes go all the way through the front casing it might have physically locked the rotor if long mounting bolts have been used as their tips may be touching against the steel rotor.

Alan
 

[Bikemad]

I have just been looking at another post showing the inside of the air cooled motor and one of the photos shows four round (threaded?) holes on the rotor:



I suspect that these holes in the rotor disc will be threaded, and would be used (along with a special puller) to pull the rotor disc off the splined motor shaft.

If the rotor disc has been pushed onto the shaft too far by installing mounting bolts that were too long, then you may be able to use some suitably threaded rod and nuts in conjunction with a solid piece of hardwood (or steel box section) across the end of the motor shaft to pull the disc back slightly:



If (after removing the circlip on the motor shaft) the motor cannot be dismantled easily, you may be able to use a simple puller (similar to the one shown above) with the threaded rod screwed into the mounting bolt holes on the front casing to gently pull the housing/bearing off the shaft.

If the centre of the shaft end has a threaded hole for a bolt, you should be able to use a piece of threaded rod and suitable lengths of wood or piece of metal tubing with a large washer and nut to gently pull the motor shaft back through the bearing and front housing again:

   

Hopefully you will be able to sort the problem with this information.



Alan

EDIT: Additional attachments added to post.