What are the assembly requirements for the stator and rotor of a model aircraft brushless motor? What are the advantages of automatic production line assembly?

The assembly of the stator and rotor of the brushless motor of the aircraft model, whether it is manual assembly or fully automated assembly, has certain requirements. The assembly work needs to be completed according to these requirements and principles. So what are the specific assembly requirements of the stator and rotor of the brushless motor of the aircraft model? What are the advantages of automatic production line assembly? Let Vacuz briefly introduce it to you!

1. Core requirements for stator and rotor assembly

1. Mechanical precision control

Air gap uniformity: The gap between the stator and the rotor must be strictly controlled within the design range. If the air gap is too large, the magnetic resistance will increase and the efficiency will decrease. If the air gap is too small, it may cause a “bore sweep” phenomenon. It is necessary to use an air gap gauge or laser measuring instrument to detect and achieve the target by adjusting the position of the stator core or rotor shaft.

Coaxiality and end-face parallelism: The coaxiality between the rotor shaft and the stator inner hole must be ≤0.02mm, and the end-face parallelism must be ≤0.05mm, otherwise severe vibration and noise will occur during high-speed rotation. It is necessary to select precision bearings, high-rigidity machine base, and optimize performance through dynamic balance correction.

Magnetic pole alignment accuracy: The relative position error between the rotor magnet and the stator notch must be ≤1° electrical angle, otherwise it will cause torque fluctuations and reduced efficiency. Encoders or Hall sensors need to be used for positioning, and high-precision alignment can be achieved through servo motor drive.

2. Electrical performance guarantee

Insulation resistance: The insulation resistance between the stator winding, iron core and chassis must be ≥100MΩ under 500V DC test to prevent leakage and short circuit. High temperature resistant insulating materials must be used, and must be dipped in paint and dried before assembly.

Turn-to-turn insulation: The turns of the winding must be kept intact without damage or burrs to withstand high-voltage pulse impacts. An automatic winding machine is used to reduce human damage, and it is verified by the inter-turn impulse voltage test.

3. Cleanliness and temperature control

Assembly environment: It must meet the 10,000-level cleanliness standard to prevent dust and metal shavings from entering the air gap and causing wear or short circuits. It needs to be assembled in a dust-free workshop and equipped with air shower and dust removal equipment.

Process temperature: Process temperatures such as dipping and drying must be controlled between 120-150°C to avoid aging of insulation materials and deformation of windings.

4. Consistency requirements

During mass production, it is necessary to ensure that the air gap, resistance, inductance and other parameters of each motor fluctuate ≤±5% to ensure product performance consistency.

2. Core advantages of automatic production lines

1. Efficient production and flexible adaptation

Full-process automation: The automatic production line can complete the entire process from stator core loading, winding, detection to rotor magnet lamination, press-fitting, and dynamic balance correction. The single-piece assembly time is shortened by more than 50%, and the production capacity of a single shift is increased by 3-5 times.

Rapid mold change capability: Through modular design (such as replaceable molds and fixtures) and intelligent operating system, it supports the production of stators and rotors of multiple specifications. Parameter adjustment and mold replacement can be completed within 15 minutes to meet the needs of small batches and multi-variety orders.

2. High accuracy and stability guaranteed

Closed-loop control technology: High-precision servo motors are used to drive the winding head and mechanical arm, with a positioning accuracy of ±0.02mm; parameters such as tension, winding speed, and number of turns are monitored and adjusted in real time to ensure the stability of winding quality.

Error-proofing mechanism: Through visual inspection and sensor feedback, winding abnormalities (such as wire breaks and jumpers) are automatically identified and corrected, and the defective product rate is reduced to less than 0.1%.

3. Quality traceability and cost control

Data interconnection: Supports docking with MES/ERP systems to realize real-time monitoring and tracing of production data, providing data support for quality management.

Labor cost optimization: An automatic production line can replace 10-15 workers, reducing the cost of a single piece in long-term operation by 30%-50%, while reducing efficiency fluctuations caused by manual fatigue.

4. Safety and environmental protection design

Safety protection: Equipped with safety gratings, emergency stop buttons and other devices to reduce operational risks.

Green production: The closed design reduces noise and dust pollution and meets the requirements of sustainable development.

What are the assembly requirements for the stator and rotor of a model aircraft brushless motor? What are the advantages of automatic production line assembly? Vacuz has given a brief explanation above. I hope this knowledge can help everyone!