Deep Understanding of the Internal Structure of an Electric Motor
Many riders aren’t fully aware of what’s inside an electric motor. Let’s take a closer look at its internal components and how they work together to make the motor run efficiently.
Starting with the magnets, which are one of the most important parts of the motor. There are several types of permanent magnets used in motors, including ferrite, aluminum-nickel-cobalt, and neodymium-iron-boron (NdFeB). Among these, NdFeB is the most commonly used in modern electric vehicle motors due to its high magnetic energy product. This allows for smaller, more powerful motors. The quality of the magnet is usually indicated by its grade—such as EH, UH, SH, H, M, or N—with higher grades offering better temperature resistance. For example, a grade like 38M means it can withstand temperatures up to 100°C, making it suitable for most standard applications.
Next, the height of the magnet plays a crucial role in performance. Thicker magnets tend to resist demagnetization better under heat, which is essential for long-term reliability. While thickness is more important than width, many manufacturers only specify the height, not the exact dimensions. So when choosing a motor, it's wise to look for magnets that are thick enough to maintain their strength over time.
Moving on to the iron core, which is typically made from cold-rolled silicon steel sheets. These sheets reduce energy loss due to eddy currents. The grade of the silicon steel determines its efficiency—higher grades like 470 or 600 have lower iron losses, meaning the motor runs cooler and more efficiently. In China, brands like WISCO and Baosteel are known for producing high-quality silicon steel, while imported materials from Germany or Japan are even better but rarely used in mass production.
Then there’s the enameled wire, which carries the current through the motor windings. Common grades include 130-2 and 180-1, where the number refers to the temperature rating, and the letter indicates the thickness of the insulation. A 180-1 wire is generally better because it can handle higher temperatures and has a thinner coating, allowing for better conductivity.
The lead wires, or eight-core lines, are another critical component. Their cross-sectional area determines how much current they can carry. For example, a 1500W motor should use at least 2.5 mm² wires, while anything smaller may risk overheating and burning out. If your motor claims to be 1500W but uses 1.5 mm² wires, it might be overrated or unreliable.
Finally, let’s talk about bearings and Hall sensors. Bearings support the motor’s rotating parts and must be strong enough to handle the torque. A 1500W motor typically needs at least a 6004 bearing, while smaller motors might use a 6203. The quality of the bearing affects both lifespan and performance, and cheaper options may wear out faster. As for Hall sensors, they act as the "door" between the motor and the controller, helping to regulate the motor’s operation. Poorly matched controllers or overheating can cause them to fail. It’s important to ensure that the controller and motor are properly synchronized to avoid unnecessary stress on the Hall sensor.
Understanding these components helps riders make more informed decisions when buying or maintaining an electric motor. Whether you're upgrading your e-bike or just curious, knowing what's inside can go a long way in ensuring performance and longevity.
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