In order to achieve high accuracy, high performance and high flexibility in the brushless motor rotor assembly production line, we need to start from the three dimensions of precision control, performance optimization and technology upgrade, and combine actual cases and key technologies to provide systematic solutions. The following is the integration and optimization of relevant content by Vacuz, I hope it can help you!

1. Precision control: closed-loop management from source to finished product

1. Precision control of key components

a. Magnet positioning accuracy

Problem: Large deviation of magnet mounting angle will lead to increased torque fluctuation.

‌Solution‌: Use visual positioning system combined with high-precision manipulator to achieve accurate control of magnet angle error. Use laser rangefinder to monitor magnet height in real time, and adjust mounting pressure through closed-loop feedback.

‌Case‌: A drone motor production line successfully reduced the magnet angle error significantly through visual positioning technology, and torque fluctuation was also reduced.

b. Rotor core concentricity

‌Problem‌: Core eccentricity will cause vibration and noise.

‌Solution‌: Use high-precision hydraulic clamps with online concentricity detectors to correct the clamp position in real time. Perform dynamic balancing correction on the core to ensure that the imbalance is within a reasonable range.

‌Case‌: A new energy vehicle motor production line significantly reduced rotor vibration through dynamic balancing correction technology.

2. Assembly process precision control

Bearing press accuracy‌

‌Problem‌: Uneven bearing press force will shorten the bearing life.

‌Solution‌: Use a servo press system to monitor the press force-displacement curve in real time to ensure that the press force fluctuation is within a controllable range. Add a temperature compensation module to adjust the press parameters according to the ambient temperature.
‌End cover assembly gap‌

‌Problem‌: Uneven gap between the end cover and the core will cause magnetic leakage.

‌Solution‌: Use a laser triangulation meter to monitor the gap between the end cover and the core in real time, and automatically adjust the end cover position through an adaptive assembly algorithm.

2. Performance optimization: synergistic improvement of design and process

1. Magnet shape optimization

Technology: Halbach array or segmented magnets are used to reduce magnetic leakage and improve air gap magnetic density.

‌Case: A servo motor successfully improved torque density by optimizing the magnet shape.

2. Magnetization process optimization

Technology: Use pulse magnetizer to achieve multi-pole synchronous magnetization to ensure magnetic pole consistency.

‌Case: A high-speed motor reduces cogging torque by optimizing the magnetization process.

3. Dynamic performance optimization

‌High-speed dynamic balancing technology

Technology: Use a semi-automatic deweighting machine to deweight the rotor at high speed to ensure that the unbalance is within a controllable range.

‌Case: A high-speed hair dryer motor significantly reduces vibration and prolongs its life through dynamic balancing optimization.

‌Temperature rise control technology

Technology: Embed thermocouples inside the rotor to monitor temperature distribution in real time, and optimize the heat dissipation structure through fluid simulation.

‌Case‌: A drone motor has effectively reduced temperature rise and improved efficiency by optimizing the heat dissipation structure.

III. Summary and Suggestions

‌1. Precision control is the basis‌: Prioritize upgrading core equipment such as visual positioning, servo press-fitting, and dynamic balancing correction to ensure that the error of key parameters is within the controllable range.

‌2. Performance optimization is the core‌: Improve torque density, efficiency and life through technologies such as magnetic circuit design, magnetization process, dynamic balancing, and temperature rise control.

3. ‌Intelligence is the future‌: Introduce machine vision, AI, digital twins and other technologies to achieve adaptive optimization of production lines and flexible production.

‌4. Data-driven is the guarantee‌: Establish a process database combined with sensor data to achieve full life cycle quality traceability.

Through the implementation of the above measures, we can achieve high-precision, high-performance and high-flexibility production of brushless motor rotor assembly production lines to meet the stringent requirements of new energy vehicles, industrial automation, consumer electronics and other fields.

Correo electrónico: sales@vacuz.com