**Deep Understanding of the Internal Structure of an Electric Motor**
Many riders aren't fully aware of what's inside an electric motor. Today, we're going to take a closer look at the internal components and how they work together to make your e-bike or electric vehicle run smoothly.
Starting with the magnets—something that car enthusiasts are always interested in. There are several types of magnet materials used in motors, such as ferrite, aluminum-nickel-cobalt, and neodymium-iron-boron (NdFeB). Among these, NdFeB is the most powerful and widely used in modern electric motors because it can generate a high magnetic energy product in a small space, which helps reduce the size of the motor. This makes it ideal for electric vehicles and e-bikes.
The quality of the magnet material is often indicated by its grade, like EH, UH, SH, H, M, N. The higher the grade, the better the temperature resistance and performance. For example, EH has a temperature resistance of 200°C, while N only supports up to 80°C. Most electric motors today use 38M or 40M-grade magnets, which have a temperature resistance of around 100°C. The numbers on the magnets, such as 35, 38, 40, represent the maximum energy product. A higher number means stronger magnetism.
Next, the height of the magnet plays a big role in performance. Thicker magnets are more resistant to demagnetization, especially under high temperatures. For instance, a 3mm thick magnet may lose less than 3% of its strength after two hours at 100°C, while a 2.5mm one could lose 5–8%. So, when evaluating a motor, thickness matters more than width.
Moving on to the core, which is usually made from silicon steel sheets. These sheets are cold-rolled for better efficiency, and their grades range from 800 down to 300. The lower the number, the better the performance, as it indicates lower iron loss. Higher-grade steel is more expensive but offers better efficiency and durability.
Then there’s the enameled wire, which is used to wind the motor coils. Common types are 130-2 and 180-1. The first number refers to the temperature rating, so 180 is better than 130. The second number indicates the paint film thickness—1 being thinner and 2 being thicker. Using 180-1 wire improves performance and reduces heat buildup.
The lead wires, also known as the three-phase lines, are another critical component. Their cross-sectional area determines how much current they can handle. For example, 1.5mm² is suitable for motors under 800W, while 6mm² is needed for 1500–2000W motors. If a 1500W motor uses only 1.5mm² wires, it might be overpowered and prone to overheating or burning out.
Finally, let’s talk about bearings and Hall sensors. Bearings support the motor shaft and affect its lifespan. A 1500W motor typically needs at least a 6004 bearing (42mm outer diameter), while smaller motors might use 6203 (40mm). Bearings come in different quality groups (Z1-Z4), with Z4 being the best but also the most expensive. Many small manufacturers use cheaper bearings, often from Cixi, Zhejiang, to cut costs.
As for Hall sensors, they act as the “door†between the motor and the controller, enabling electronic commutation. If the controller isn’t properly matched, the Hall sensor can easily get damaged. In some cases, even if the controller cuts off power due to overheating, the motor may continue running as a generator, potentially damaging the Hall sensor if it stops at the wrong position.
Understanding these components helps you choose a better-quality motor and avoid common issues like overheating, demagnetization, and sensor failure. Whether you’re building your own e-bike or just curious, knowing what’s inside can make a big difference in performance and longevity.
Industrial PC
Industrial PC, specifically designed for harsh industrial environments, possess many notable features. Industrial PCs have excellent stability and can operate stably for a long time under harsh conditions such as high temperature, humidity, and dust, ensuring that the production process is not disturbed. Its strong anti-interference ability is another highlight, which can effectively resist electromagnetic interference and power fluctuations, ensuring the accuracy and reliability of data transmission. Industrial computers also have a high degree of durability, with a sturdy casing and protective design that can withstand impact and vibration. In terms of performance, it has efficient computing power and fast data processing speed, which can easily cope with complex industrial control and monitoring tasks. For example, in automated production lines, industrial computers monitor the real-time operation status of equipment, timely detect and solve problems; In the intelligent warehousing system, precise management of goods in and out of storage improves logistics efficiency.
The application fields of Industrial All-In-One PC are very extensive. In the manufacturing industry, it is the core control equipment of automated production lines, accurately controlling various machines, improving production efficiency and product quality. In the field of intelligent warehousing and logistics, it is possible to achieve rapid sorting of goods, inventory management, and real-time tracking of logistics information. In the medical industry, industrial all-in-one pcs are used for the control and data acquisition of medical equipment, such as medical imaging equipment, ward monitoring systems, etc. In the field of energy, it plays an important role in power monitoring, petrochemical production, and other aspects to ensure the safety and stability of energy production. In addition, the signal control and intelligent transportation management of rail transit in the transportation industry also rely on industrial integrated machines. For example, in automobile manufacturing factories, industrial all-in-one machines help achieve the automation process of automobile assembly; In large hospitals, all-in-one pcs ensure the stable operation of medical equipment and accurate recording of data.
Industrial Panel PC play a crucial role in numerous extreme environmental scenarios due to their wide temperature characteristics. In the cold northern factory workshop, even if the temperature is extremely low, it can still operate stably, used for monitoring and operating production equipment, real-time display of equipment operating parameters, and convenient for workers to adjust and maintain in a timely manner. In the hot desert areas of the power industry, wide temperature protection ensures its normal operation under high temperatures, used for remote monitoring and scheduling of substations, to ensure the stable operation of the power system. In mine operations with large temperature differences, it can also adapt and provide safety monitoring data and communication support for workers. For example, in extremely cold cold storage, industrial panel computers can accurately control temperature and inventory management; Real time monitoring of production processes in high-temperature steel plants.
In intelligent security monitoring systems, Fanless Panel PC play a crucial role, demonstrating excellent adaptability and reliability. Firstly, in the monitoring center, fanless industrial computers can undertake centralized processing and analysis tasks for a large amount of video data collected by surveillance cameras. Its powerful computing power can quickly identify and filter out abnormal behavior, suspicious individuals or vehicles, and issue alerts in a timely manner. Due to the absence of noise generated by fan operation, it will not interfere with the working environment of monitoring personnel, allowing them to focus more on handling emergency situations. Secondly, in outdoor monitoring equipment, the fanless design effectively prevents foreign objects such as dust and insects from entering the computer interior, reducing the risk of equipment failure. Whether in hot summers, cold winters, or even harsh weather conditions, fanless industrial computers can operate stably, ensuring uninterrupted transmission and storage of monitoring data. Furthermore, in scenarios such as border security and important facility protection, fanless industrial pcs can work in conjunction with intelligent recognition software and sensors. For example, in border areas, it is possible to accurately identify illegal cross-border activities; Real time monitoring of unauthorized access around important facilities. For example, in the security monitoring system of a large commercial park, fanless industrial panel pc can not only process high-definition video streams from hundreds of cameras 24 hours a day without interruption, but also automatically distinguish between normal personnel activities and potential security threats, such as abnormal intrusion or abnormal stay at night, through intelligent analysis algorithms. In some remote monitoring stations, their fanless and low-power characteristics enable equipment to operate reliably even under unstable power supply conditions such as solar or wind energy.
In the field of intelligent transportation, Embedded Computer are installed in road monitoring equipment. For example, at toll stations on highways, computers are embedded in control boxes to process vehicle information in real-time, achieving rapid toll collection and traffic management. In terms of medical equipment, such as large X-ray machines and industrial computers embedded in the body, precise control of radiation emission and image acquisition and processing provides accurate diagnostic basis for doctors. On industrial automation production lines, embedded industrial computers are installed in the control unit of the robotic arm to accurately command actions, ensuring efficient and high-quality production of products. In addition, industrial computers are embedded in the intelligent distribution cabinets of the power system to monitor power parameters in real time and ensure the safe and stable operation of the power grid.
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