Brushless motors are one of the most commonly used types of motors, aside from brushed motors. Brushless direct current (BLDC) motors do not utilize mechanical brushes; instead, they employ square wave self-controlled permanent magnet synchronous motors, replacing carbon brushes with Hall sensors for commutation. Compared to traditional DC motors, they offer significant advantages in performance, such as high efficiency, low energy consumption, low noise, long lifespan, high reliability, and the capacity for servo control.
A.Inner Rotor vs. Outer Rotor
1.Rotation Position Difference: The inner rotor, where the electric drive part is located internally and the casing remains stationary while the interior rotates; the outer rotor has a stationary interior with the exterior casing rotating. Generally, the part with embedded magnets (permanent magnets) will rotate, while the coil part will not. Depending on the embedding process and position of the permanent magnets, one can distinguish between outer and inner rotors.
2.Permanent Magnet Volume: The outer rotor has a smaller volume of permanent magnets and a smaller axial dimension, leading to better system stability during operation. The inner rotor has a large volume of permanent magnets, and correspondingly larger axial dimensions, higher center of gravity, and poorer operational stability.
3.Speed: Taking the same DC brushless motor as an example, the inner rotor motor will have a higher speed than the outer rotor motor.
4.Application: Inner rotors are commonly applied in power machinery such as motors, generators, gas turbines, and compressors, while outer rotors are typically installed in impellers, serving the role of heat dissipation and cooling.
In the field of intelligent equipment manufacturing, HONEST Automation, with over a decade of professional experience, stands as a leading enterprise in the manufacturing of motor production lines. We provide services to several top-tier automobile manufacturers and have been honored multiple times with the “Outstanding Supplier” award by our clients. This recognition is an affirmation and motivation for our continuous innovation and relentless pursuit of service optimization.
We exercise strict quality control over every aspect of the cooling fan motor production equipment, including the rotor, stator, bracket, PCB, and rear cover components. This reflects our commitment to delivering high-quality products.
We will provide a detailed introduction to the key production equipment and testing machines on HONEST Automation’ brushless outer rotor cooling fan motor production line, showcasing our professional capabilities in ensuring the production performance of brushless cooling fan motors.
B.Production Equipment
1.Rotor Shell Feeding Machine
Our rotor shell feeding machine utilizes advanced technology with an automatic positioning buffer box to ensure the precision of rotor component delivery. Mechanical arms precisely grip and place the components into the CCD photography jig for inspection, followed by rapid transportation on an accelerated chain conveyor, forming an efficient and high-quality production process. The design of this equipment effectively prevents damage to the rotor shell during the production process, ensuring product performance.
2.Lamination Gluing Machine
The machine automatically receives materials via an accelerated chain conveyor. After the motor components are transported to the rotary disc workstation, they sequentially undergo flipping, CCD photography, glue application, and flipping again. Precise glue quantity and even distribution of the adhesive provide strong assurance for the sealing and durability of the motor components.
3.Magnet Attachment & High-Frequency Curing & Cooling Machine
The equipment features automatic feeding functions for the rotor casing and magnets, coupled with an automatic scanning mechanism, facilitating traceability of the production process. The design of the magnet expansion jig ensures the magnets are tightly attached to the rotor casing; high-frequency heating equipment heats the external coil of the rotor for curing, ensuring rapid curing of the rotor.
The automatic return flow of the demolding magnet jig, along with the automatic transportation of the rotor assembly to the cooling tunnel furnace for cooling, further accelerates production speed and saves human resources.
4.Stator Winding Machine
As we all know, the stator winding process is a critical step that directly affects the performance and reliability of the motor. HONEST Automation stator winding machine integrates automatic material feeding, dual-station winding, position sensing, and automatic scanning functions, ensuring the winding process is efficient and accurate. By working in concert with precision wire arrangement and a servo tensioner, it achieves precise tension control. Meanwhile, a break-wire alarm mechanism ensures product quality and the continuity of the production process.
In terms of quality control, our equipment utilizes a data traceability system that enables the tracking of enameled wire batches and stators, ensuring the traceability of products.
5.Metal Terminal Welding Machine
Our welding machine employs advanced automatic butt welding technology, sequentially welding metal terminals to ensure that each welding point meets quality standards. After the welding is completed, the high-speed chain system automatically transports the product to the next workstation, achieving smoothness in the production process.
6.Stator Component Bearing Assembly Equipment
The handling components place the stator into the fixture, and the automatic feeding and pressing of the bearings are realized, a step that ensures the precise fit between the bearings and the stator, laying a solid foundation for the stable operation of the motor. We strictly control the operations during the assembly process to ensure no damage to the bearings and terminals, maintaining their integrity.
7.Stator and Rotor Assembly Machine
Our stator and rotor assembly machine has a high degree of automation, achieving automatic material feeding and scanning for the stator and rotor, ensuring the accuracy and traceability of the production process. With the spring bowl’s automatic feeding combined with the automatic sorting and grabbing mechanism, the components are precisely placed into the elastic dummy shaft, and sensors detect them, effectively preventing missed installations. Finally, pressure sensors test the elasticity and assembly dimensions to ensure they meet requirements. Qualified products can then be discharged. This automated assembly process ensures high standards and quality in the assembly process.
C.Testing Equipment
1.Rotor Iron Shell Runout Test Equipment
Testing the runout of the rotor iron shell is a critical step in ensuring the assembly quality and operational precision of the motor. It is determined by measuring the runout of the end face of the rotor iron shell during rotation. If the runout exceeds the specified tolerance range, it may lead to additional vibration and noise during motor operation, affecting the motor’s performance and lifespan.
The equipment is highly automated, eliminating the need for manual involvement. This not only saves human resources but also reduces potential errors associated with manual testing, thereby improving the efficiency and accuracy of the testing process. Products that fail the test are automatically directed to a designated defective area, ensuring uninterrupted production flow and consistent product quality.
The runout test range of our equipment can be customized according to specific customer requirements to meet the needs of products with different performance characteristics.
2.Dynamic Balancing Test Machine
Dynamic balancing testing of the motor rotor is performed to determine the imbalance of the rotor and to correct it, thereby improving the mass distribution of the rotor relative to the axis and reducing the vibration or vibration forces acting on the bearings during rotation. HONEST Automation’s dynamic balancing test machine, with its high precision and automation features, and a balance quantity test accuracy of ±5mg, provides a fundamental guarantee for the quality balance of the motor rotor. Products that fail the test are automatically directed to an NG box without causing interruptions in the production process.
In the design of the rotor dynamic balancing test machine, HONEST Automation also offers customized services. The requirements for imbalance quantity, imbalance test accuracy, and measurement rotation speed range can be adjusted according to the specific needs of the customer and the actual production conditions of the product.
D.The Advantages of HONEST Automation
1.Customized Non-Standard Services: HONEST Automation offers tailored design services for critical indices such as the inner diameter of the potting machine, the distance from the outer end face of the magnet to the inner bottom face of the casing, the gap between the magnets, and the press-fit size of the bearings in the stator assembly. These customizations are made according to the customer’s needs and the actual production situation of the product, ensuring that the customer’s production can be carried out efficiently and swiftly.
2.Traceability of Production Process Data: Equipped with an automatic scanning function, the entire production process can be traced. This feature is instrumental in controlling and supervising the production process, ensuring its stable operation.
3.Intelligent Automation in Production: By adopting advanced automation technologies, we significantly reduce the involvement of manual labor, enhancing production efficiency and accuracy.
The production performance of cooling fan motors is influenced by every component and the manufacturing process. To ensure the stability and high quality of motor performance, it is essential to produce high-quality stators and rotors in the production stages. HONEST Automation is confident in our ability to design cooling fan motor production equipment that is both high-quality and stable in performance. Should you have any further needs or inquiries regarding brushless outer rotor cooling fan motors or other related production and testing equipment, please feel free to contact us at any time.
