E-BIKE 48V Brushless Motor Controller Teardown Failure Analysis
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- Опубликовано: 13 сен 2024
- Teardown of E-BIKE brushless motor controller LSW979-122M to determine cause of failure. This just stopped. This module was replaced by manufacturer with no need to return defective unit. Entire module was potted and I just tore apart to see what was inside and mostly just to use as a case for future product.Totally potted and non repairable. Had to cut case to get electronics out.Three half bridge drivers to form a three phase motor controller with three high current wires for motor drive. Five additional smaller wires to motor hub to sense temperature and magnetic position sensor.
After teardown was started I noticed that of the three power pins for the motor drive, one was missing. It was still there but had burned up. Wire was sufficient for current.Connector was definitely not sufficient for the 12A rating. Informed owner that the motor side connector was likely also damaged and the problem would likely happen again.
One option is to carefully cut into both cables and jumper the bad pins externally if it happens again and the unit is out of warranty. Owner is currently negotiating to get a new hub so all cable connections are new.
Those other little pins on the Connector are for the Hall Sensors.
I redid the video to shorten it and left that information out.
Yea the Chines get right down to the Wire with the Wire, Arr Arrr. On my Hub motor the wire that should be like 14 or 12 AWG is only like 16AWG. 1000W motor should be pulling 2oA @ 48V and they use 16AWG ? Ok each leg on the motor should only be realizing 1/3 of the 20A but all the same. Even the Primary Power Leads are only like 16AWG wire.
#16 is rated for 22A for internal wiring. Derated some as a bundle depending on insulation. It is like the Chinese took online courses from MOLEX on how to over rate connector current.
@@opera5714 LOL, As long as you remember the Chinesium Rating system equates to half of everyone else's standards we're good to go. Chines Amper = 0.5 SAE Amperage.
Horrible name for your channel you either get Oprah Winfrey or Opera I guess Italian musicals. But it's nice to see somebody understand it's great to find the problem but you also need to find out what caused the problem. difference between mechanic and good mechanic electrician
I thought the name would keep YT riff raff away. It comes from Nantucket, the historic Seamans Opera House. Probably just a brothel. Started as Opera House Boat Works, I do own a full size pipe organ. Then it was Operahouse and now just opera. My first job was repairing transistorized organs in 64 when I was 14. They had no choice, I was the only one who understood transistors. My brother had to drive me on service calls. 60 years of repair and electronics design and the problem is usually bad design.