Hidden factors affecting the quality of brushless DC motors.
The advantages and characteristics of brushless DC motors need no further elaboration. Today, let's take a look at something different. In the production and manufacturing process of brushless DC motors, there are many factors that affect their quality, including some implicit and explicit factors.
There are still many hidden factors that affect the quality of brushless DC motors:
1. The rotor or rotor core should be hot fitted onto the shaft
In the production and manufacturing of motors, the main function of heat sleeve equipment is to promote the integration of the rotor, thereby ensuring that the rotor of the motor reaches a certain strength. However, in actual production, it can be seen that if there is a slight heating phenomenon in the rotor, it will cause a large gap between the iron core and the shaft, resulting in an unbalanced air gap. In the vibration of the motor, the noise pollution is relatively large. However, these phenomena are not visible to the outside, so operators can easily overlook them.
2. The welding machine base should have a thorough aging process
The inadequate aging of the welding machine base is the main cause of deformation. Even if this phenomenon occurs, it will not cause any operational problems in a short period of time. Usually, it can only be detected within six months. So, the difficulty of inspection work is relatively high. Specifically, the variation in coaxiality is also an important factor affecting motor vibration. The degree of bearing damage can be determined from the intensity and frequency of noise.
3. Immersion paint
The so-called immersion paint usually refers to the immersion paint of the winding, which is not very obvious in actual production and manufacturing. If the quality of the immersion paint is not up to standard, there will be a phenomenon of absorbing moisture and reducing insulation strength. Moreover, the winding is not easy to dissipate heat, and during long-term operation, there may be temperature rise and damage to insulation equipment.
4. Iron core
The efficiency of motor operation is easily affected by the quality of the iron core, including factors such as power parameters and noise. The poor quality of the iron core indicates that its installation pressure is too loose, and the consumption of iron is relatively high. If the temperature continues to rise, burrs will cause serious harm to the insulation equipment and shorten the service life of the winding. Severe cases can also generate certain electromagnetic noise, causing the operation of the motor to lose balance.
5. Binding of the end of the formed winding
For the formed winding, it is necessary to tightly tie its ends and leave an appropriate amount of gap. This is mainly to avoid damage to the winding when starting the motor and ensure the highest heat dissipation efficiency. For this stage, a typical representative is Germany, which never neglects the binding of windings in the production and manufacturing of motors.
6. Insert rotor
During the operation of a brushless DC motor, when rolling bearings, it is necessary to install end caps on both ends of the rotor to avoid bearing damage as much as possible. Motors with appropriate electrodes are not allowed to have excessive gaps, so relevant personnel need to pay more attention to the rotor insertion of the motor
7. Copper bar rotor welding
The welding requirements for copper bar rotors are relatively strict, usually requiring them to be carried out in a certain state, and the state cannot be changed. Otherwise, it will form a diamond shape.
8. Bearing assembly
The most important thing in bearing assembly is to maintain a clean assembly environment. Operators should not wear gloves. If it is a sliding bearing, the staff needs to pay more attention. But if it is a rolling bearing, a layer of lubricating grease needs to be applied.
