Reasons for Struggling Motor Operation

The motor is one of the four key components of an electric vehicle, converting the electrical energy from the battery into mechanical energy to propel the vehicle. If not properly maintained, the motor’s lifespan can shorten, or it may even fail entirely. Regular maintenance and care are essential for prolonging its life. A malfunction in one part of the system can affect the performance of other components. If the motor is running with difficulty, timely repairs are necessary.

If the motor is struggling to run, it’s important to check if the issue is related to internal motor failure or a braking problem that is hindering its performance. When the motor struggles to rotate, the current increases, leading to more energy consumption and potentially causing other components to work harder, thereby reducing their lifespan.

1. Brake Faults

Since electric vehicles rely entirely on battery power, many riders may not pay attention to minor struggles while driving, assuming that as long as the vehicle moves, it’s fine. However, issues with the brakes can cause significant power loss. A faulty brake system could be caused by several factors: a broken brake spring that doesn’t rebound, rust in the brake cable, or worn-out brake pads. If the brake is either too tight or too loose, it can make braking harder, preventing proper disengagement and ultimately limiting motor performance.

Solution: Replace the brake cables and pads with high-quality parts and adjust them appropriately to ensure smooth operation and reduce strain on the motor.

2. Motor Bearing Failure

Electric motors are sealed, but they are still susceptible to water and moisture ingress, which can cause rusting and corrosion over time. This can lead to increased friction in the motor bearings, causing abnormal sounds, wobbling of the rear wheel, and difficulty in motor operation. When this happens, the rotor and stator can misalign, causing additional load and increasing power consumption, which leads to overheating and further damage.

Solution: Avoid exposing the motor to water. If you hear abnormal noises, address the issue immediately. Replace the bearings with high-quality parts and lubricate them properly. Use sealing glue around the motor’s end cover to prevent moisture ingress.

3. Stator Failure

The stator, typically made from laminated silicon steel and three-phase windings, can be prone to deformation due to water exposure and rust. A rusted or deformed stator may cause uneven rotation, leading to periods of easy and difficult operation. When water and rust introduce foreign particles or “rust stains” inside the motor, the stator and rotor may begin to rub against each other, leading to inefficient motor operation.

Solution: If the motor becomes difficult to turn, repair it immediately. Select high-quality stators made from rigid materials with pure copper windings to avoid premature failure. Avoid cutting corners to save costs, as this can lead to serious long-term problems.

4. Magnet Failure (Broken or Detached Magnetic Steel)

Magnetic steel is crucial for the motor’s magnetic field. If the motor is exposed to moisture or rust, the magnets can become magnetized with increasing rust, which interferes with the magnetic field between the poles (north and south). A broken magnet can create an additional magnetic pole, leading to disordered magnetic lines and preventing the motor from operating smoothly.

Solution: Open the motor and carefully remove the stator. Look for any detached magnets, clean any rust, and reattach the magnets with resin glue to restore the motor’s functionality.

5. Burned or Blackened Coils

In an effort to reduce costs, some motors are built with subpar copper wire or fewer coil windings. When the motor operates under heavy load, the excessive heat can burn the coils, causing short circuits that make the motor either run inefficiently or fail completely. In some cases, the controller may malfunction, causing the motor to seize up. Forcefully attempting to push the vehicle can also damage the coils.

Solution: Avoid overloading the vehicle and choose a motor from a reputable brand that offers both strong power output and energy efficiency. If the controller fails and the motor doesn’t turn, cut the thick wires of the motor to prevent further damage.

Conclusion

To ensure the smooth operation of an electric motor, it is essential to maintain regular checks for brake system faults, bearing conditions, stator alignment, magnet integrity, and coil health. Timely repair and quality replacements are crucial for preventing unnecessary strain on the motor, ensuring that it operates efficiently and lasts longer.