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Best eBike motor - Macvol Surge

Mid-drive motor vs. hub motor

Hub E-Motor: Geared motor & Gearless (Direct-drive) motor

Direct-drive, gearless motors have no moving parts other than bearings and transfer all power to the wheels through the motor. This is great for high speeds, but less efficient at low speeds. They also often provide regenerative braking.
Geared hub motors use a series of gears within the motor to reduce the speed of the motor to produce a greater torque output. The torque is great for stopping and starting and steep terrain. These are better suited for hilly areas or carrying cargo

Mid-drive motor

A mid-drive motor is installed on the frame in the middle of the bicycle, replacing the bottom bracket. The mid-drive motor uses a series of gears inside the motor to generate torque, causing the axis connected to the chainring to rotate. This system has many advantages. The motor is able to use internal gears to reduce the speed of the axis, resulting in a higher torque output. This optimizes the performance of the motor and maintains a comfortable pedaling frequency for the rider.
All mid-drive motors are brushless DC motors, which means they draw power directly from the battery source. They use data from three different sensors: a torque sensor, a cadence sensor, and a speed sensor. The data is calculated 1,000 times per second to provide a smooth output through the steel drive shaft.
The torque sensor of modern mid-drive systems is very sensitive, which means that the motor can determine how much power you need based on the power input you provide. In other words, the torque sensor determines how much power you input and gives you more torque accordingly. Therefore, if you feel that you are not fully utilizing the power of the motor, it is likely that your gear ratio is too low and you have not provided enough torque to the system. This is where the cadence sensor comes in. The cadence sensor determines your pedaling speed based on the number of revolutions or revolutions per minute.
Ideally, a mid-drive motor would like your pedal cadence to be between 50 and 80 RPM. Therefore, if you pedal at a speed higher than 90 RPM on a very low gear, the mid-drive motor will not be able to provide you with full power. The mid-drive motor we provide can support a wide range of pedal cadences. For example, the Macvol motor can provide power up to 110 RPM. This wide range of pedal cadences is helpful for steep inclines, but you always want to keep your pedal cadence within the range of 50 to 80 rotations per minute. This is where the pedal cadence and torque sensors work best together. Ultimately, this is why the mid-drive motor system is superior to any other system because it combines both torque and pedal cadence sensors to provide smooth power delivery.
Many people are concerned whether their mid-drive motor is based on a cadence sensor or torque sensor, but ultimately all the mid-drive motors we sell combine these two sensors to make these systems superior to other mid-drive motors and hub drive motors on the market.
We prefer mid-drive motors because they provide a true cycling experience by using pedal assist instead of the throttle commonly found on hub-driven bicycles. Throttles not only weaken the cycling experience, but also decrease the lifespan of the motor as they often overheat and create more stress than mid-drive motors.

Why a mid-drive motor is the right choice for eBikes

One reason why mid-drive motors work so well is because of their reliability. There are several reasons why they are more reliable than hub-drive motors. Because they are in a fixed position, only internal components are in motion, which creates less stress and wear than hub-drive motors that rotate with the wheels. In addition, because of its position, a lot of air will surround the motor, keeping it cool. Electronic components and heat are not very compatible. You need a mid-drive motor that can dissipate heat well. The modern mid-drive motors we sell have a variety of unique cooling designs and devices to keep the motor cool while riding.
Another reason why these in-wheel motors are so reliable is that they are completely enclosed internally and not affected by external environmental factors. This means that rainwater and dust cannot enter. In addition, any connection ports are locked together without any splicing or welding of connections to the motor. Improperly spliced or welded wires may cause weak connections. Locking the wire harness and connecting it to the motor by the manufacturer will prevent many of the connection problems we see with hub drive motors.
The efficiency of electric bicycles with mid-drive motors can be further optimized by using the transmission system's gears, whether through a derailleur and gearset or an internally geared rear hub. The higher torque output and efficiency make mid-drive motors the preferred choice for electric mountain bikes and other performance-focused e-bikes, providing excellent electric assistance for steeper terrain. The torque sensor on mid-drive motor e-bikes also provides a more natural pedaling feel, which is crucial for cyclists seeking electric assistance but don't want to lose the feel of a non-electric bike.
Motor efficiency may be the most important factor to consider in an electric bike system. Battery size, motor size, and how the motor manages power output are important. While hub motors with high power (watts) and throttle control can provide fast speeds and endless fun, they require a lot of energy (a large battery) to keep you moving. Mid-drive motors have a smaller total power output, but provide high torque output. Working in conjunction with the bike's drivetrain, mid-drive motors require less energy (a smaller battery) to provide electric assistance.
To summarise the advantages and disadvantages of mid-drive motors over hub motors.
  • Efficiently, using bike gears allows for the motor to optimize its power consumption
  • Motor location keeps the bike feeling balanced between the wheels
  • Higher torque outputs, ideal for steep terrain and heavy loads
  • Manages heat better for more strenuous sustained use
  • Torque sensor makes a more natural pedaling feel when engaging the motor
  • Rear wheel maintenance is unaffected by the motor
The only disadvantage of a mid-drive motor compared to a hub motor is its more complicated structure, which leads to a higher price.

Why Macvol surge e-motor is better than others

 

High Efficiency

High energy efficiency means longer range, continuous high intensity climbing motor temperature will not be too high.
For the Smart gear, when the output torque range is 8~15N.m, it is comparable to the Normal gear, and when the output torque range is 15~90N.m, it is the same pattern of the motor output boost curve as the Turbo gear, but with different absolute values.
Output torque range in different modes for Surge 100 and Surge 200
 

 

Flat Wire Winding

Only MACVOLTRACK and Bosch have flat wire windings. Flat wire windings have a larger high efficiency range and a wider wide efficiency range
 
  1. For the same power, smaller size, less material, lower cost or for the same size, higher slot filling rate, higher power density.
  2. Larger winding cross-sectional area, less dense, lower resistance, higher efficiency at heavy load point.
  3. Better temperature performance, less internal clearance, better contact between flat wires and flat wires, between windings and core slots, larger contact area, better thermal conductivity.
  4. Flat wire windings are more rigid, and with the optimization of the rotor pole structure can have better NVH performance; the result is a 10% increase in true copper slot fullness, and the 10% increase can be converted into a variety of directions (volume, weight, and energy efficiency) Tandem chose to use this 10% for energy efficiency improvement.

True copper slot fullness increased by 10%

Comparison of flat wire and round wire motor efficiency map charts

In comparison, Bosch motors are not able to guarantee a continuous output of 250W at a temperature of less than 60 degrees Celsius in the motor casing, so in accordance with European Union standards, a high temperature label is required on the outside of the motor. MACVOLTRACK's high power output and efficient heat dissipation design enable Surge e-Motor to keep the temperature within the EU standard.

 

Integral Potting of Motors

Only MACVOLRACK and Shimano motors have potting compound.
 

The motor potting process usually refers to the use of potting adhesive (also known as encapsulating adhesive) to seal and secure the inside of the motor to prevent moisture, dust or other impurities from entering the motor, thereby significantly improving the performance and life of the motor. The advantages are as follows:

  1. Dust and moisture resistance: Potting compound can effectively seal the inside of the motor to prevent dust, moisture and other impurities from entering, thus protecting the internal parts of the motor from damage and corrosion.

  2. Improve insulation performance: Potting compound can improve the insulation performance of the motor and prevent short circuit between electrical components, thus improving the safety and reliability of the motor.

  3. Reduce vibration and noise: Potting compound can fix the internal parts of the motor, reduce vibration and noise, and improve the smoothness and comfort of the motor.

  4. Improve durability: Through the potting adhesive process, the internal parts of the motor can be better fixed and protected, thus prolonging the service life of the motor.

 

Mute Optimization

A variety of approaches have been used to fully optimize the quiet performance of the motor.
 
  1. Material optimization: the gears are made of a single piece of peak material, the material grade is kept confidential and the noise generated by the friction between the gears is reduced while ensuring the same stiffness as the metal material.
  2. Process optimization: after the assembly of all components in the motor is completed, all components are fixed with potting adhesive, and the cavity is filled with adhesive to ensure that there is no noise generated by vibration between the components, to improve the overall stiffness, to reduce electromagnetic noise, and to fan the heat quickly.
  3. Dynamics simulation optimization: improve the support stiffness of the system, optimize the transmission error of the system, the sound pressure level at the human ear decreased by 7.3dBA

Noise testing at the human ear position.

Dynamics simulation.

Cycling Experience

Minimum pedal stroke.
 

Pedaling air travel in a cycling motor is the minimum distance or angle that the pedals must move down before pedaling begins. This air travel is usually detected by a sensor in the motor controller to trigger the generator to start and provide power support.

The Surge series motors have a ratchet clutch with a small amount of air travel (6° or less), which makes for a good pedaling experience (PS: the larger the air travel angle, the more pronounced the feeling of stepping out of the way when pedaling), while the market competes with air travels ranging from 6.92° to 7.2°.

The Surge series motors have a single ratchet slot spaced 12° apart and two sets of 6 ratchets in total, keeping pedal travel within 12/2=6°.

 

Manufacturing, Assembly Processes

Vehicle-grade device selection, one-piece plug-in electronic control process, fully automated production line.
 

  1. The circuit control unit of the motor, including the main control MCU, drive and power MOS, torque sensor are all automotive-grade chips, which are superior to competitors in terms of temperature rating, reliability, functional safety and life rating.

  2. The one-piece electronic control connection greatly improves the stability and reliability of the system, avoiding frequent shaking and high and low temperature impacts that cause the wiring harness to fall off and aging.

  3. Surge series motors are fully automated in Vietnam to ensure the stability of quality and consistency of performance. Most of the competitors do not have automated production lines.

One-piece connector

Flying lead wiring