Maintenance and Repair Techniques for Electric Tricycle Differential Motors

Differential motors are widely used in the three-wheeler industry due to their high torque and excellent climbing and carrying capacity. Most electric tricycles currently use differential motors.

As the driving and transmission device of three-wheelers, the differential motor transmits power to both sides of the vehicle through the central “differential” gear, causing the two wheels to rotate at different speeds.

So, what are the common faults of electric tricycle differential motors, and how can these faults be repaired?

Common Electric Tricycle Differential Motor Faults:

1. Motor Malfunctions: Motor issues often involve Hall sensor problems and internal mechanical problems in the differential.
   • Hall Sensor Check: Use a multimeter set to the 20V range. Connect the red probe to the positive line of the Hall sensor and the black probe to the yellow, green, and blue lines one by one. Then, turn on the power lock and gently rotate the motor wheel. If the voltage changes, it indicates that the corresponding Hall sensor is functioning correctly. The voltage change typically ranges from 0-5V. If the voltage remains constant, it suggests a faulty Hall sensor that needs replacement.
   • Disassembling the Differential Motor: The motor and the differential are usually separate components. If it has a hexagonal cap, clean any dirt attached to the cap using a pointed tool before disassembling.
   • Taking Apart the Components: Arrange the disassembled components in order. Be cautious when handling magnets inside to prevent attracting foreign objects.
   • Replacing the Faulty Hall Sensor: After detecting a damaged Hall sensor, gently tap it off using a pointed tool. When soldering the Hall sensor, avoid prolonged heating to prevent damage. Fix the Hall sensor in place using adhesive and secure the wires with cable ties. Reassemble the motor, ensuring that all screws are tightened.
2. Differential Gearbox Faults: Differential gearbox issues are typically mechanical and can involve problems with bearings or gears. In such cases, it’s recommended to replace the entire gearbox.
3. Changing Gear Oil: Use the upper and lower screws on the motor’s differential gearbox to change the gear oil. It’s advisable to change the oil every six months. Drain the old oil and replace it with the appropriate gear oil. Ensure that you don’t overfill the oil to prevent it from entering the braking system.
4. Oil Leakage from the Differential: Oil leakage is usually due to damaged seals. Replace the seals to prevent gear oil leakage, which can lead to damage to the motor.
5. Overheating of Motor Phase Lines: The powerful differential motor can overheat if there are loose connections. Properly solder the wires to ensure they have a secure connection and prevent overheating.

By following these maintenance and repair techniques, you can address common issues with electric tricycle differential motors, ensuring they function effectively and have an extended lifespan. Regular inspection and proper maintenance are crucial for the reliable operation of electric tricycles.