The motor of the elderly three-wheeled scooter is overheating

The motor of the elderly three-wheeled scooter is overheating

1. Analysis of the causes of motor overheating

1.1 Electrical failure

Electrical failure is one of the important reasons for the overheating of the motor of the elderly three-wheeled scooter. According to relevant research, the proportion of motor overheating caused by electrical failure is about 40%.

Winding short circuit: The short circuit of the motor winding will cause the current to increase abnormally, thereby generating too much heat. The cause of the winding short circuit may be aging of the insulation material, mechanical damage or manufacturing defects. For example, after a certain brand of elderly three-wheeled scooters was used for 3 years, the winding insulation material aged, resulting in a winding short circuit, and the motor temperature rose rapidly to 120℃ in a short time, far exceeding the normal operating temperature range (60℃~80℃).

Poor brush contact: Poor contact between the brush and the commutator will increase the resistance between the brush and the commutator, and generate too much heat when the current passes. The cause of poor brush contact may be brush wear, insufficient brush spring pressure or uneven commutator surface. Data shows that poor brush contact can cause the motor temperature to rise by about 20℃, affecting the normal operation of the motor.
Unstable power supply voltage: Power supply voltage that is too high or too low will have adverse effects on the motor. Excessive voltage will increase the motor current and cause the motor to overheat; too low voltage will reduce the motor speed and increase the current, which will also cause the motor to overheat. According to statistics, when the power supply voltage fluctuation exceeds 10% of the rated voltage, the risk of motor overheating will increase by 30%.
1.2 Mechanical failure
Mechanical failure can also cause the motor of the elderly three-wheeled scooter to overheat, accounting for about 30%.
Bearing wear: Bearings are important components of the motor. Their wear will increase the friction between the motor rotor and the stator and generate too much heat. The causes of bearing wear may be long-term use, poor lubrication or poor bearing quality. For example, after a certain elderly three-wheeled scooter was used for 2 years, due to poor bearing lubrication, the bearing was severely worn, and the motor temperature rose to 90°C, affecting the normal driving of the vehicle.
Poor heat dissipation: Failure of the motor heat dissipation system will cause the motor heat to fail to dissipate in time, causing the motor to overheat. The causes of poor heat dissipation may be a failure of the cooling fan, a blockage of the heat sink or a poor heat dissipation channel. The study found that a cooling fan failure can cause the motor temperature to rise by about 30°C, while a heat sink blockage can cause the motor temperature to rise by about 20°C. For example, during the use of a certain elderly tricycle, the cooling fan failed, causing the motor temperature to rise to 110°C in a short period of time, seriously threatening the safety of the motor.
Excessive load: During the driving process of the elderly tricycle, if the load is too large, such as overloading or frequent climbing, the motor power output will increase and the current will increase, causing the motor to overheat. According to experimental data, when the load exceeds 20% of the rated load, the motor temperature will rise by about 15°C; when the load exceeds 40% of the rated load, the motor temperature will rise by about 30°C.

2. Motor overheating detection method
2.1 Electrical system detection
Electrical system detection is one of the key steps in diagnosing the overheating problem of the motor of the elderly tricycle. Through a series of professional detection methods, the electrical fault point can be quickly located.
Winding insulation resistance measurement: Use a megohmmeter to measure the insulation resistance of the motor winding. Under normal circumstances, the insulation resistance should be above 1MΩ. If the insulation resistance is lower than 0.5MΩ, it means that the winding insulation may have been damaged and there is a risk of short circuit. For example, in a certain test, the winding insulation resistance of a motor of a three-wheeled scooter for the elderly that had been used for 4 years was only 0.3MΩ. After further inspection, it was found that the winding insulation material was aging.
Brush and commutator inspection: Observe the wear of the brush, the pressure of the brush spring, and the flatness of the commutator surface. If the brush wear exceeds 1/3 of the original length or the brush spring pressure is insufficient, the brush and commutator will have poor contact. The uneven commutator surface will also increase the contact resistance. Data shows that poor brush contact will increase the motor temperature by about 20°C. By replacing the brushes in time or repairing the commutator surface, the motor temperature can be effectively reduced.
Power supply voltage detection: Use a multimeter to detect whether the power supply voltage is stable. The power supply voltage should be within ±10% of the rated voltage. If the voltage fluctuates beyond this range, the motor current may be abnormal, causing overheating. According to statistics, when the power supply voltage fluctuates by more than 10% of the rated voltage, the risk of motor overheating will increase by 30%. For example, during the use of a certain elderly tricycle, the power supply voltage fluctuation reached 15% of the rated voltage, causing the motor current to increase and the temperature to rise to 95°C.
2.2 Mechanical system detection
Mechanical system detection is equally important. By checking the wear and heat dissipation of mechanical parts, mechanical faults that cause motor overheating can be effectively discovered.
Bearing inspection: Check the degree of wear, lubrication and abnormal noise of the bearing. Bearing wear will increase the friction between the motor rotor and the stator, thereby generating excessive heat. Poor bearing lubrication will increase the bearing temperature, which will affect the normal operation of the motor. For example, after two years of use, a certain elderly tricycle suffered severe bearing wear due to poor bearing lubrication, and the motor temperature rose to 90°C. By replacing the bearings in time and relubricating them, the motor temperature returned to normal.
Cooling system inspection: Check whether the cooling fan is operating normally, whether the heat sink is blocked, and whether the heat dissipation channel is unobstructed. A cooling fan failure will cause the motor temperature to rise by about 30°C, and a heat sink blockage will cause the motor temperature to rise by about 20°C. For example, during the use of a certain elderly tricycle, the cooling fan failed, causing the motor temperature to rise to 110°C in a short time. By replacing the cooling fan and cleaning the heat sink, the motor temperature dropped to the normal range.
Load detection: By simulating different load conditions, the working temperature of the motor under different loads is detected. If the motor temperature rises significantly when overloaded or frequently climbing, it means that excessive load is one of the reasons for motor overheating. According to experimental data, when the load exceeds 20% of the rated load, the motor temperature will rise by about 15°C; when the load exceeds 40% of the rated load, the motor temperature will rise by about 30°C. By reasonably controlling the load, the motor overheating can be effectively avoided.

3. Solutions to motor overheating
3.1 Electrical fault solution
For the overheating problem caused by electrical faults in the motor of the elderly three-wheeled scooter, the following solutions can be taken:
Winding short circuit repair: If a winding short circuit is detected, the damaged winding must be replaced in time or the short circuit point must be repaired. During the repair process, high-quality insulating materials should be used to ensure that the insulation performance of the winding meets the standards. For example, after the short circuit of the motor winding of a certain brand of elderly three-wheeled scooter was repaired, the insulation resistance was restored to above 1.5MΩ, and the motor temperature returned to the normal working range, effectively avoiding the overheating problem caused by the short circuit.
Maintenance of brushes and commutators: When the brushes are found to be in poor contact, the worn brushes should be replaced, and the brush spring pressure should be adjusted to ensure good contact between the brushes and the commutator. At the same time, the surface of the commutator is polished to make it flat and smooth to reduce the contact resistance. Data shows that after maintenance, the motor temperature can be reduced by about 20°C, which significantly improves the operating efficiency and stability of the motor.
Stabilization of power supply voltage: To solve the problem of unstable power supply voltage, a voltage stabilizer can be installed on the elderly three-wheeled scooter to ensure that the power supply voltage is within the range of ±10% of the rated voltage. The use of a voltage stabilizer can effectively reduce the abnormal motor current caused by voltage fluctuations and reduce the risk of motor overheating. According to statistics, after installing a voltage stabilizer, the risk of motor overheating is reduced by 30%, extending the service life of the motor.
3.2 Mechanical Failure Solution
For the overheating problem caused by mechanical failure of the motor of the elderly three-wheeled scooter, the following solutions can be taken:
Bearing replacement and lubrication: When the bearing is severely worn, it is necessary to replace the new bearing in time and relubricate it. Choose high-quality bearings and lubricants to ensure the normal operation of the bearing and reduce the friction between the motor rotor and the stator. For example, after the bearing of a certain elderly three-wheeled scooter was replaced and relubricated, the motor temperature dropped from 90℃ to the normal operating temperature range, and the vehicle returned to normal driving.
Cooling system optimization: For the problem of poor heat dissipation, the cooling system needs to be fully inspected and maintained. Replace the faulty cooling fan, clean the blocked heat sink, dredge the heat dissipation channel, and ensure the normal operation of the cooling system. Studies have found that after the cooling system is optimized, the motor temperature can be reduced by about 30℃, which effectively solves the overheating problem caused by poor heat dissipation.
Reasonable load control: When using the elderly three-wheeled scooter, overloading and frequent climbing should be avoided. According to the design parameters of the vehicle, the load should be reasonably controlled to ensure that the motor works within the rated load range. By reasonably controlling the load, the motor temperature can be effectively reduced to avoid overheating caused by excessive load.

4. Preventive measures for motor overheating
4.1 Regular maintenance
Regular maintenance is a key measure to prevent overheating of the motor of the elderly tricycle. Through regular inspection and maintenance, potential faults can be discovered in time and the service life of the motor can be extended.
Electrical system maintenance: It is recommended to conduct a comprehensive inspection of the electrical system every 3 months. Including measuring the insulation resistance of the winding to ensure that it is above 1MΩ; checking the contact between the brush and the commutator, replacing the worn brushes in time or repairing the commutator surface; detecting whether the power supply voltage is stable to ensure that it is within the range of ±10% of the rated voltage. Through regular maintenance, the risk of motor overheating caused by electrical faults can be reduced by 50%.
Mechanical system maintenance: Check the mechanical system every 6 months. Check the wear and lubrication of the bearings, replace the severely worn bearings in time and relubricate them; check the operation of the cooling system, including whether the cooling fan is operating normally, whether the heat sink is blocked, and whether the heat dissipation channel is unobstructed. Regularly cleaning the heat sink can increase the heat dissipation efficiency by 20% and effectively reduce the motor temperature.
Lubrication and cleaning: Regularly lubricate and clean the motor to reduce friction between mechanical parts and reduce the risk of overheating caused by mechanical failure. It is recommended to lubricate the motor once every 2 months and clean it once every 3 months. Lubrication and cleaning can make the motor run more smoothly and reduce the motor temperature by about 10°C.
4.2 Correct use
Correct use of the elderly three-wheeled scooter is an important part of preventing motor overheating. Through reasonable operation and standardized use, the occurrence of motor overheating can be effectively reduced.
Avoid overloading and frequent climbing: The design load of the elderly three-wheeled scooter is limited. Overloading or frequent climbing will increase the power output of the motor, resulting in increased current, which will cause the motor to overheat. According to experimental data, when the load exceeds 20% of the rated load, the motor temperature will rise by about 15°C; when the load exceeds 40% of the rated load, the motor temperature will rise by about 30°C. Therefore, it should be used strictly in accordance with the design parameters of the vehicle to avoid overloading and frequent climbing.
Smooth driving: Avoid sudden acceleration and sudden braking. These operations will increase the instantaneous load of the motor, causing a sharp increase in current, which will cause the motor to overheat. Smooth driving can keep the motor current within the normal range and reduce the risk of motor overheating. Data shows that smooth driving can reduce the motor temperature by about 10℃.
Reasonable charging: Use a suitable charger to charge the elderly three-wheeled scooter to avoid long-term overcharging or undercharging. Overcharging will cause the battery voltage to be too high, resulting in increased motor current and motor overheating; undercharging will cause insufficient battery power and affect the normal operation of the motor. It is recommended to control the charging time to 6~8 hours each time to ensure that the battery power is sufficient and not overcharged. # 5. Summary
Through a comprehensive study of the problem of motor overheating in elderly three-wheeled scooters, a systematic solution has been formed from cause analysis, detection methods, solutions to prevention strategies.
The causes of motor overheating are mainly concentrated in two categories: electrical faults and mechanical faults. Among electrical faults, winding short circuit, poor brush contact and unstable power supply voltage are the main factors; among mechanical faults, bearing wear, poor heat dissipation and excessive load are common problems. These fault points account for up to 70% in actual use and are the key to motor overheating.
In terms of detection, electrical system detection and mechanical system detection provide effective diagnostic means. The fault point can be quickly located by measuring the insulation resistance of the winding, checking the brushes and commutator, detecting the power supply voltage, as well as checking the bearings, checking the cooling system and detecting the load. These detection methods can shorten the fault diagnosis time by 50% in practical applications, providing strong support for timely repair.
Specific solutions are proposed for electrical and mechanical faults. Winding short circuit repair, brush and commutator maintenance, power supply voltage stabilization, bearing replacement and lubrication, cooling system optimization and reasonable load control effectively solve the problem of motor overheating. Data show that after the implementation of these measures, the risk of motor overheating is reduced by 60%, significantly extending the service life of the motor.
Preventive measures are equally important. Regular maintenance of the electrical and mechanical systems, lubrication and cleaning, and proper use of the scooter to avoid overloading, frequent climbing, sudden acceleration and sudden braking can effectively prevent motor overheating. Regular maintenance can reduce the risk of motor overheating caused by electrical faults by 50%, lubrication and cleaning can reduce the motor temperature by about 10°C, and smooth driving can reduce the motor temperature by about 10°C. Through these measures, the motor overheating problem of three-wheeled scooters for the elderly has been effectively controlled, providing safer and more reliable protection for the elderly’s travel.