Wire-cutting anyone?

[halfmedley]

After a few delays (weather and time mainly) my Synergie Mistral is finally on the road and proving to be great fun. Is cycling really meant to be this easy? The Mistral seems to have plenty of grunt to get me up the 10 percents no problem. Next step: regular commute.

On to my main question: one of my delays was caused by me trying to fit slime-filled inner tubes and Schwalbes to minimise the risk of puncture. Fitting the rear turned out to be quite a challenge. The wire to the hub motor disappears up the spindle and is no doubt hard-wired within, so trying to fit a new tyre without wrenching this wire out was tricky. I did it eventually.

So, I was wondering whether it might be an idea to cut this wire and then rejoin it with one of those lego-brick type connectors. Then should I ever have to remove the rear wheel again I could uncouple the wire and not have to worry at all about putting any undue tension on it, or wrenching it out by accident. Anybody else done this? Is this a practical solution or a route into chaos? Are the any 'electrical' issues (such a current flow) that preclude this idea?

I must say the idea of cutting wires fills me with some trepidation, but then so does damaging a hidden internal connector, which would be impossible or expensive to fix.

Your thoughts as always are most welcome.

 

[rsscott]

I would choose a connector than can be pulled apart without having to use a screwdriver to loosen the wires on those chocolate block connectors. On my Torq eZee have used crimp-on terminals which can be pulled apart.

The only other thing you will need to do is to ensure the subsequent 'modification' is waterproof!

cheers
Russ.

 

[flecc]

As Russ advised. The cheap looking automotive plug in tubular connectors handle the current ok, and the Torq uses three of them for the main motor feeds. The current carrying is the main thing, the connectors must be able to handle around 20 amps for the phase feeds.

There's also five thin wire signal feeds from the Hall sensors on the Hall effect motors. These don't carry much current and a light connector is ok, but secure connections are essential on these since any connection loss can cause severe vibrational stress to the motor. A really good quality DIN 5 pin connector could do that job, but there's not much choice around for these in the UK now. Radiospares have very good quality similar design IP67 type 5 pin connectors which look like DIN ones but have thicker pins.

 

[halfmedley]

Thanks for the advice, food for thought indeed.

It seems that there are just two wires exiting the hub via the spindle, would this suggest that the motor is brushed rather than hall-effect? (Excuse my electrical ignorance!).

 

[flecc]

Yes, seems it's a brush motor, so only necessary to have those auto connectors handling to 20 amps. You might find a cardpack of those large crimp-ons in Halfords.
.

 

[Baboonking]

When i was first starting to playing around with electric bikes i use 30amp lego connectors. They're a bit fidly and they do rust but if you do them up tight you get a good connection because of the compression of the metals. always a good idea to grease the wire and connectors through as this prevents oxidation.

You could you smaller brick connectors for the halls effect cables. its untidy but it will work. you can seal them with silicone and then duck tape. messy but does work.

I your looking to do a tidier job: my favorite is anderson powerpoles which you can get from 4qd. there quick release so very quick to pull apart. For the halls effect cables like flecc says 5 pin din connectors are great, you can get them from maplin or ebay or a local electronics shop. soldering them is very fidly though.

I'm pretty sure the synergy bikes have brushless motors, maybe the contoller is in the hub?

 

[flecc]

I'm pretty sure the synergy bikes have brushless motors, maybe the contoller is in the hub?

I wondered about that momentarily and was surprised that it didn't appear to be Hall effect, hence my saying "seems", but I thought it unlikely they'd do that. I had a look at the ebay specification but it avoids any mention other than "200 watt high efficiency motor". They would say that. wouldn't they!

 

[Baboonking]

Strange isn't it. I can find no information on what they use either. I suppose its conceivable its a brushed hub motor.

 

[flecc]

It is strange, and the fact they don't mention the obvious selling point of Hall effect makes me think it probably is brush, with the Li-ion battery giving the high tech impression. No problem though, brush motors are still doing a good enough job on many bikes, Heinzmann, Currie, eZee Rider/Liv etc.