Maintenance This section contains some simple electric vehicle problem repair and motor fault problem handling, practical and easy to learn. First, the common faults and troubleshooting methods of electric vehicles: 1, the meter display is normal, the motor does not turn (1) Cause of failure: 1 brake damage determination; 2 speed control handle damage determination; 3 motor damage determination; 4 controller damage; (2) Troubleshooting: 1 Unplug the brake lever socket (normally open brake lever). If the motor is running, it is a brake failure and the brake lever should be replaced. 2 Turn the source 5V voltage to normal, detect the turn signal voltage, turn the handle, the signal voltage should be from 0.8 to 4.2V from low to high. If there is no change in voltage and less than 1V, there is a short circuit in the fault of the switch or the switch wire. If the voltage is greater than 1V and the change is normal, the motor Hall signal (yellow, green, blue lines) is detected. If the three-phase Hall signal line voltage is all 5V and the contact is good, the motor Hall is damaged, and the motor or motor Hall element should be replaced. 3 separately detect the motor Hall signal line, and slowly rotate the motor by hand. The voltage of each phase should be changed between 0 and 5V. If the voltage is not changed, the motor Hall is damaged. The motor or motor Hall element should be replaced. If the voltage of each phase changes normally and the power supply is normal, the controller is damaged and the controller is replaced. 4 Use a multimeter to detect the input voltage of the controller power supply. The voltage should be greater than 36V (the battery is fully charged). If there is no voltage, check the input line. Check the controller to turn the power supply voltage (connected to the red and black lines of the switch), the normal voltage is 5 ~ 6V, if there is no 5V voltage, unplug the switch socket, the voltage is restored to 5V, it may be short circuit of the motor Hall element, such as If there is still no 5V voltage, the controller is faulty and the controller should be replaced. 5 First check whether there is a short circuit at the beginning of the speed control switch and the motor Hall. Generally, the joint is short-circuited after rain and damp. Therefore, pay attention to the waterproof joint. If the controller is damaged, you should first check the switch before replacing the new controller. Is the motor Hall switch shorted? Failure to do so will result in continuous damage to the replacement controller! 6 or the motor does not turn, focus on the motor Hall switch and turn signal, if the power is on, the controller shell is very hot, generally the controller internal power tube short circuit, should cut off the power immediately. 2, the motor stops when the time (1) Cause of failure 1 The battery voltage is in an undervoltage critical state. 2 Poor contact in the battery connector. 3 speed control turn the line to break. 4 The brake power off switch has failed. 5 The power lock is damaged and the contact is poor. 6 line connector is not properly connected. 7 The components inside the controller are not welded firmly. 8 The carbon brush and wire group in the motor have a virtual weld. (2) Troubleshooting 1 Check the battery voltage and recharge the battery. 2 Adjust or replace the plug. 3 Reconnect the speed control switch leads. 4Adjust or replace the brake power off switch. 5 Replace the power lock. 6 Re-plug the line. 7 Replace the controller. 8 Replace the motor. 3, the motor does not turn, the meter has no display (1) Cause of failure 1 The fuse is burned out. 2 The battery is damaged. 3 battery line broken soldering open circuit. 4 power lock is broken. 5 Poor contact of battery contacts or plugs. (2) Troubleshooting: Use the multimeter voltage block to detect the battery output voltage. If there is no voltage, check the fuse and the fuse holder, the battery, and the battery connection cable for open circuit. If the battery output voltage is normal, check the controller power supply. The terminal voltage, if no voltage, check the cable lock and cable for disconnection and poor plugging. 4, the motor speed is slow (1) Cause of failure 1 The speed control handle is damaged. 2 The battery capacity is insufficient or not charged. 3 The controller has failed. 4 The motor has failed. (2) Trouble-shooting 1 Detect the speed control hand-holding speed signal line (green line) voltage. When the turning point is at the maximum angle, the speed-regulating terminal voltage should be 4.2V. If it is less than this voltage, the electrode speed will be slow, and the speed control handle should be replaced. 2 Recharge the battery. 3 Replace the controller or motor. 5, motor jitter (brushless) (1) Cause of failure 1 Motor Hall connector is defective. 2 Turn the handle bad. 3 speed signal line has interference. (2) Troubleshooting: 1 Motor Hall connector is defective, re-plug. 2 Turn the contact bad, re-plug. 3 speed signal line has interference, try to change controller and instrument. 4 Electric bicycles produce jitter during use, which is generally caused by poor contact between the motor Hall switch connector and the switch connector. Therefore, it is important to check the connectors, especially the motor Hall switch connectors. 6, the motor is noisy (1) Cause of failure: 1 The bearing gap in the motor is large. 2 motor rotor broom. 3 The magnetic steel is loose and falls off. 4 The internal motor is axially moved. 5 The brush motor commutator surface is oxidized, ablated, oily, uneven, and the commutator is loose. 6 carbon brush holder loose, carbon brush holder is not correct. (2) Troubleshooting: 1 Replace the bearing. 2 Repair the stator and rotor again. 3 Re-bond the magnetic steel. 4 Add a suitable washer in the axial direction. 5 Clean the surface layer of the commutator or weld the commutator. 6 Adjust the carbon brush holder. 7, speed (1) Cause of failure: 1 The speed control switch is damaged or the ground wire (black wire) is broken or the plug is defective. 2 controller failure (brushed). (2) Troubleshooting: 1 Disconnect the speed control. If it is normal, the controller is normal. Check the speed control and ground. When the speed is turned off and the rear car is still not stopped, the controller is damaged and the controller is replaced. 2 If the power supply wheel turns, the incremental speed is very fast, which is called "speeding", and most of them are caused by the bad contact of the grounding wire. Therefore, it is important to check the grounding of the switch. 8, the instrument panel has no power display, the motor is running normally (1) Cause of failure: 1 There is no voltage between the positive and negative leads of the meter, and the wire or connector is short-circuited. 2 The instrument is damaged. (2) Troubleshooting: Use the multimeter DC 50V file to detect the positive and negative voltages of the meter. If the voltage is normal, the meter is damaged. No voltage, the wire or connector is broken, check the cable and connector. 9. The instrument voltage display is normal, the speed display is abnormal, and the motor is running normally. (1) Cause of failure: 1 The instrument is damaged. 2 speed signal line (black/white) short circuit. 3 controller has no speed display. (2) Troubleshooting: brushed and 48V brushless: use the multimeter voltage block to detect the speed signal line and the positive pole of the power supply (48V brushless detection speed signal and negative pole). The potential varies with the motor running speed and the voltage changes from low to high ( The 36V model has a 0 to 36V change, the 48V brush has a 0 to 48V change, and the 48V brushless has a 0 to 25V change. If there is no change, should the speed signal line plug be checked? Is there a short circuit? If the voltage changes normally, it is a malfunction of the instrument. If the speed display is low, use a screwdriver to adjust the speed adjustment potentiometer on the instrument panel to normal. 36V brushless: Check the instrument panel and controller speed line (black/white) cable for short circuit. If normal, connect the controller speed signal line to the motor Hall line (fine yellow, green, blue). If the speed is normal, the controller is damaged. If there is still no display, the small instrument is damaged. 10, the speaker is out of control (1) Cause of failure: 1 speaker is damaged. 2 The horn switch is damaged. 3 The cable or connector is shorted. (2) Troubleshooting: 1 After pressing the horn switch, use the multimeter voltage block to detect the voltage across the speaker cable. If the voltage is normal, the horn will be damaged. If there is no voltage, the horn switch is damaged or the wire is broken. By shorting the two-wire test of the horn switch, you can quickly find the fault point. 2 If the positive and negative poles of the electronic horn are reversed, the horn has no sound. 11, the headlights are not bright (1) Cause of failure: 1 bulb is broken. 2 headlight switch is broken. 3 wire or connector short circuit. (2) Troubleshooting: The maintenance method is the same as the maintenance speaker. 12, the turn signal is not bright (1) Cause of failure: 1 The flasher is damaged. 2 The turn signal switch is damaged. 3 wire or connector short circuit. (2) Troubleshooting: The left and right flashes are not lit at the same time, and the flasher is likely to be damaged. If the left turn signal is not lit and the right turn signal is on or the right turn signal is off and the left turn signal is on, the flasher is intact and the steering switch and lamp should be checked. 13, continuous burning fuse (1) Cause of failure: 1 The controller is damaged. 2 The meter is shorted. 3 lamp holder short circuit. 4 The cable is short-circuited after being damaged. 5 Reverse the battery positive and negative poles (after replacing the battery or using other brands of battery boxes). (2) Troubleshooting: Unplug the battery, open the switch, and turn off all the lamps and lanterns. Use a multimeter to electrically block the resistance between the measuring plugs (simple car contacts). If the resistance is very small, close to 0Ω, it means that the line has a short circuit, which can be detected by the open circuit method. If the power connector of the controller is unplugged, the power is restored to normal, indicating that the controller is damaged. If it is still not normal, the instrument can be pulled out and tested, and so on. If the headlight or turn signal switch turns on the burnt fuse, check the headlight base or the turn signal lamp holder for short circuit. 14. The battery has insufficient mileage after one charge. The continuation mileage is full when the new battery is used. The rider's weight is 75kg, the ambient temperature is (25±5°C), the wind speed is no more than 3m/s, and the flat is two. Ride on the grade road, ride to the battery voltage less than 10.5V to power off, get the ride and mileage under the above conditions. There are many factors that affect the mileage of the continuation: for example, the battery is old and new, a new set of batteries, the actual "continuation mileage" may exceed 50Km, and the "continuation mileage" of the battery used for a period of time will decrease. This is mainly due to the decrease in battery capacity over time. In addition, the actual load weight, whether the road surface is flat, whether there is ups and downs, wind speed, wind direction, braking during driving, number of starts, whether the tire is sufficient and the correct charging method, the temperature of the use environment, etc. will affect the actual The mileage is "yes (the current mileage is reduced by about 0.5km for every 1 °C drop at a standard temperature of 25 °C). 15, quickly find the electric bicycle failure and troubleshooting method does not turn the car (that is, the motor does not turn) (1) (When the power is on, turn on the power lock) Use a multimeter to measure the motor lead with or without voltage, and immediately determine the fault between the controller and the motor lead or the control line. 1 The voltage is measured, then it is determined that the motor is broken or the controller If there is an open circuit fault between the motor leads, it should be excluded. If the 2 measurement results have a voltage, then it is determined that the controller line is faulty and the next step should be checked. (2) Measuring method: disconnect the controller brake power-off plug, and then transfer the adjustment handle 1 If the car rotates, it is determined that the brake power-off switch is broken, causing a short-circuit fault, and the brake power-off switch 2 should be replaced. If the car does not turn, replace the original speed control handle test with a good speed control handle. If the car rotates, it is determined that the original adjustment handle is broken, causing the motor not to rotate, the new handle should be replaced. If the motor is still not moving with the new speed control handle, it is determined that the controller is broken and should be replaced with a new controller. (3) Measure the battery box contacts, and immediately determine the fault caused by the power supply. Measurement method: Use the multimeter DC voltage block to measure the battery box contacts, whether there is voltage display: 1 If there is no voltage display, turn on the power lock, the meter If the disc pointer light is not bright, then it is determined that a, the fuse tube fuse is broken, the wire is broken, and the welding head is broken. If there is voltage display, the power lock is turned on, and the instrument panel display light is not lit, then it is determined that the power lock is broken, not Power on, you should use a new lock to open the power lock, the car does not stop, can not brake (shock phenomenon) Check method: disconnect the controller and the speed control handle plug (three-wire plug 7, 8, 9), can be immediately determined Fault of the speed control handle or controller: 1 After disconnecting the speed control handle plug, turn on the power lock and do not turn, then conclude: the speed control handle is broken, should be replaced with new one; if the photosensitive sheet or magnetic steel sheet falls off, it should be re After installing or pasting 2 disconnecting speed control handle plug, turn on the power lock or not, then conclude: the controller is broken, the power lock should be replaced to open the power supply or the battery pack fuse is not burned. Disconnect the controller power plug Immediately determine the fault. 1 After disconnecting the power plug, turn on the power lock, such as blowing the fuse, then conclude: a, most of the short circuit; b, the speaker is short-circuited; c, the power lock is short-circuited; d, the instrument panel If there is a short circuit, it should be excluded. 2 After the battery plug is connected, disconnect the top corner plug and open the power lock. If the fuse is no longer blown, then it is determined that the motor is faulty and should be checked. Targeted repair or replacement 3 If the fuse is burned after being operated according to the method of 1, 2, it is concluded that the controller is faulty, and there is another case where the controller 4 is replaced, the fuse tube model is improperly selected, and the allowable current is less than the required value ( The fuse is too thin), can not withstand the electric bicycle current, should choose 20A fuse speed slow (motor speed is low) 1 pair of photoelectric speed control handle, open the handle, take out the photosensitive film, if the motor resumes operation and normal, can conclude that the photosensitive film is too dirty , affecting the transmittance caused the speed of the car to slow down. The new photosensitive film should be cleaned or replaced (at the same time, the light-emitting device should be cleaned once). 2 Use the multimeter DC voltage block to measure the controller power supply voltage and the motor lead voltage, and turn the speed control handle. The voltage change should be below 1V. If the change exceeds 1V, Then conclude: the controller is faulty, should be replaced when the 3 motor rotates, no abnormal noise, or the motor casing is overheated during operation (hand touch hot), then it is determined: the motor is faulty, should be repaired or replaced 4 battery voltage is too low, The no-load voltage is lower than 36V. Under the operating condition, it will be close to the under-voltage state, the moving car is small, the speed is slow, and there is no strength. The reason is in the battery. The possible reasons are: a. The running mileage is too long, the electric energy is exhausted, and it should be charged in time; b. After the battery is full, the stroke is less than 12.5Km, indicating that the battery life is terminated. The battery should be replaced. The charger is faulty. The battery is not fully charged, but it is mistaken to think that it is sufficient, causing the speed to be too slow and lacking. It should be repaired or replaced in time so that the battery can be charged as soon as possible. 6 There is no problem in the motor itself and there are problems in the manufacturing. The only way to solve this problem is to replace the qualified motor. Second, motor maintenance knowledge: 1. How to determine whether the electric motor is 60° or 120°? A: Unplug (disconnect) the Hall plug and then open the door lock. Slowly turn the handle, the motor has a message indicating that the motor is 60°. If a little news is not 120°. 2. How to change the 60 degree motor to a 120 degree motor? A: Turn the motor on, and install a Hall in the middle. It can be changed to 120 degrees. 3. The electric car was originally replaced by 2 wire brakes, how to connect the wiring? A: The three lines are composed of red (+5 volts), black (ground), and green (brake signals). Such brakes are called electromagnetic brakes and are known as ABS brakes. The brakes on the new controller are 2, you only need to connect the black line and the brake signal to the new one. The red line can be used. 4. What should I pay attention to in the brushless electric car? What is the difference between Halls in different motors? A: First of all, look at the order in which Halls are arranged. The side with words is positive and the side without words is reversed. If the motor is arranged in positive, positive and positive directions, it is 60 degrees. If it is arranged in positive, negative or positive, it is a 120 degree motor. It is best to change all the Halls of the same model. The welding should be fast and accurate, and the wiring should be connected in the original order. Brushless motor is generally divided into 120 degrees and 60 degrees. The time to change should look at the location of the previous Hall? If you can change a Hallless controller if the controller is also broken, it won't be too much trouble. 5. How to determine how many watts of electric motor motor? How can I know if it is 60 degrees or 120 degrees? A: Simple cars are generally 180-250 watts, pedals are generally 350 watts, and electric motors are generally 500-800 watts! Then there is the stencil on the motor! The three Hall components in the brushless motor are all placed in parallel with a 60 degree motor! If there is a motor that is placed at a 180-degree angle, it is a 120-degree motor! Electric vehicles are generally 250W, 350W, electric motorcycle is 500W, 750W. The motor has a steel stamp on which there is power. 6. How to quickly detect whether the brushless motor is good or bad (regardless of Hall element)? Answer: Simple method: When the three phase lines are suspended, the motor should be free of resistance by hand, and any two phase wires are short-circuited. The motor has obvious interruption resistance and the resistance is consistent. 7. The three-in-one electronic horn is replaced by an iron horn. How to wire it? A: All the way, find the switch that turns, then follow the line on the turn signal switch to find the line connecting the three-in-one speaker, find the horn switch, and then follow the line to find the speaker line. The same is true for other lines. 8. How to check the battery quality, how to detect the battery capacity? Answer: Discharge directly with electric wire and then measure the voltage. The voltage drop is different and the current is fast, and the battery is finished. 9. Brushless motor has a winding wire and any other short circuit, no resistance, what to say, it does not matter? A: Explain that one of the lines has been broken. If the three thick lines are in contact, they should have resistance. If one of them has no resistance, it will be broken. 10. The positive pole of the electric vehicle has about 6v of electricity. Will it lose power and the loss is serious? A: Leakage, use a shaker to test step by step. The exclusion method is resolved. 11. After a few months of loading a new battery, I found that I can't jump the light. The same is true for the charger. Can the manufacturer retreat like this? A: It should be retired, but the manufacturer will only change the maintenance battery for a certain period of time. In a few months, you can't jump the lights. It takes at least a year to appear... water shortage. The battery light does not change, it is so hot that it is deformed. 12. Volume Hall Topic - Is the amount of brushless motor Hall more accurate with a mechanical multimeter? Answer: Use the digital meter to measure the quantity. 1. Turn the meter to the DC 20V position, turn on the power supply, and connect the black test lead ground wire (black line) red to the yellow-green-blue slowly turn the motor to see if there is 0-5v. The voltage is good. Or turn the watch to the test break and open the plug of the Hall and the controller. The resistance of the motor Hall is connected with the black pen and the red is connected to the yellow, green and blue. First of all, if you suspect that Hall has a problem, you can turn on the motor. Connect the detector to the motor cable and use a small magnet to test it back and forth on the Hall. As long as the detector's lamp is off, it will be normal. If it is always bright or often off, topic. 13.A: Today, a friend turned to a car and the motor squeaked. Install the controller on other vehicles. After careful inspection, it is found that the motor turns a ring and removes the mechanical fault. After opening the motor, it is found that a piece of magnetic steel is broken (not falling off) and an incomplete piece (large half of the manufacturer's caulking) is replaced. It still seems that only the Hall controller is replaced. B: The work is so bad, it may be the problem of uneven magnetic field, Hall can not be correctly positioned. My friend said that I also encountered the same problem as you. I am a peace tram. After the motor has changed the Hall and the controller, it is the same as the one you said. I have tried it many times. Finally, it is normal to install a Hallless controller. 14. When checking the line, sometimes there is a table that doesn't work. I have encountered the use of a meter to have electricity, but it does not work. There is no voltage in the voltage, it is the virtual voltage of the battery. It will fall after the load. 15. How to change the 60° controller of Yuen Long to 120°? A: Change the pull-down resistor of the 4 pin of the chip to pull up. 16. Why is the taillight normal after an electric car is not removed? A: Try changing the tail light bulb. There are brake lights, brake lights or lamp holders leaking, causing the brake signal to pass directly through the filament to the ground. 17. How to use high level brakes for low level brakes? Answer: You can change it, and directly connect a diode on the turn signal line (the diode positive pole is connected to the turn signal), and the diode negative pole can be connected to the brake handle line. 18. Old burning controller and turning handle? Answer: A: The controller uses the intelligent controller of Tianjin Songzheng 4815E. The meter is equipped with power assist and fixed speed display. When the user comes, the meter has no power display, and the acceleration has no reflection. Check and find the controller, turn the handle, the instrument is bad, everything is normal after the replacement, but who knows that it has just come back for two days, the fault is still the same, there is no way to change the motor together, the user drives home a few days and again The same problem occurred. B: Is there any leakage, poor contact, broken skin, etc. in the main cable? The line did not find the problem, but found that the power sensor was abnormal. After unplugging it for two days, I found that the problem was not reproduced. I wonder if this is the reason. 19. A small bird electric car was built today. Her charger is broken, I changed the charger of Wuxi Yuanneng to two bad ones, and both of them are burning resistors positive and negative. I have no problem to read or understand why? A: Use the multimeter to determine the positive and negative terminals of the battery and the positive and negative terminals and voltage of the charger. Some batteries also have positive and negative polarities. The red is negative, the black is positive... The bird's electric car's N is negative, L is positive, confirm it! 20.A: 48V500W brushless electric motor, the speed is slower, the same is the same for the two turns. Directly shorting the positive 5V and the signal line, the speed is normal, is there a problem with the controller? I have encountered such a fault before, and I have to open the speed limit line. But I don’t know if this is a problem. B: First try to open the controller speed limit. If you can't do it, try another new controller. If it is changed, it means that the original controller's switch line input resistance has become too big, which is not good. Wrap the speed limit line separately, maybe the speed limit line hits the water. 21. The negative pole of the electric car is grounded, will it lose battery power? A: Yes, the mileage will be short and the leakage will be severe. You can't let the electric car's negative pole be grounded, and the electric car and motorcycle are different. During the maintenance process, I felt that most of the electric three-wheel (serial-excited motor) was grounded on the negative pole, and as a result, it was charged several times. The grounding of the negative pole is very dangerous, and it will be charged when it rains. 22.A: The controller tests whether it is good or bad according to the commonly used method. The red is connected to the power supply negative, the negative connection is connected to the three-phase line, and the measurement is more than 500 points. The reverse is also the same. The data should be said to be The tube did not burn. The problem encountered is that when the controller just removed the car, the test data is not normal, and it is replaced by a controller problem. It is concluded that the controller is broken, but why the controller time has been put on for some days, and then measured, data It is normal again, like the tube is not burning. B: At this time, there is electricity in the controller capacitor (some tubes may be in conduction state). After a few days (or several hours or a few minutes), the capacitor is not available, and the data is normal. . I have nothing to do and I like to use the controller to buy the new controller. But in practice, I never use the table to measure the experience. I can judge whether the controller is good or not. The easiest thing is to learn from my teacher. Try it directly on the new controller. This thing has to be exchanged by everyone to become ingenious. It is not practical to measure the controller with a multimeter. Or change it and try it. However, some basic things can be measured. 23. Publish your own measurement method for the quality of the brushless controller. First, power failure detection (with diode file) 1. Detect the controller power supply input positive and negative poles early or short circuit 2. Detect controller winding wire parameters: a. Connect the positive pole of the power supply with a black pen, and touch the yellow, green and blue winding wires with a red test pen. The parameters are between 400-700. b, repeat the steps of 2 3, Hall signal line detection: black line with black pen, red pen connected to red, yellow, green, blue four lines, there should be no short circuit fault The measured resistance is not very standard. In actual maintenance, you need to combine your usual maintenance experience. Even if it is a controller, you measure it at two different times, and its resistance is different. Don't follow the steps, please use it flexibly! Citation Source: Complete Works of Electric Vehicle Maintenance Knowledge SHENZHEN YGHQ Optoelectronics Co.,ltd. , https://www.leds-smd.com