Brushless motors represent an advanced motor technology, widely applied across various fields for their high efficiency, low noise, long lifespan, and high reliability. These motors have eliminated the brushes and commutators found in traditional motors, instead utilizing electronic controllers for current commutation, which reduces wear and maintenance costs.

 

The core components of a brushless motor include a permanent magnet rotor, a wound stator, and an electronic driver. The magnetic field generated by the stator coils interacts with the permanent magnets on the rotor to produce torque, propelling the motor to rotate. The design not only enhances the motor's performance but also results in a more compact structure and reduced weight.

 

The control methods for brushless motors are primarily divided into two types: sensored control and sensorless control. Sensored control relies on Hall sensors and other devices to detect the rotor's position, while sensorless control uses algorithms to detect the back electromotive force (EMF) and estimate the rotor's position. In terms of technological development, sensorless control, and commutation torque ripple suppression are current research hotspots in the field of brushless DC motors. The study of these technologies helps to further enhance the performance and application range of brushless motors.

 

 

Market Analysis of Brushless Motor Development

 

Market Growth Trend: The global brushless DC motor market is exhibiting a continuous growth trend, which is attributed to technological advancements and innovations, the increasing demand for environmental protection, and the support of national policies.

 

Market Size and Cost-effectiveness: With the reduction of raw material costs and the effect of mass production, the production cost of brushless motors is continuously declining. The decrease in costs, coupled with their excellent performance, is further expanding the scale of market application.

 

Demand Increase:The application of brushless motors in the fields of industrial automation and robotics is becoming more widespread. As Industry 4.0 develops and the demand for automated production increases, the market demand for brushless motors is also on the rise.

 

In all, we know that the brushless motor market has broad development prospects, but at the same time, it will also face fierce market competition. To gain an advantage in the competition, the key lies in being able to provide brushless motor products with stable performance and leading technology.

 

HONEST - Your Ideal Partner

 

As a brushless motor manufacturing equipment manufacturer with rich experience, HONEST has been committed to providing customers with high-quality products and services, helping them to gain an advantage in market competition and obtain more market share. We believe that with our professional technical level and in-depth understanding of market demand, HONEST will be the suitable choice for you.

 

We will showcase our advanced technology to you through our key production and testing equipment from our brushless motor production line.

 

Demonstrating the Technical Strength of HONEST through Key Production Processes

 

A.Stator Pressing and Gluing Machine

 

Positioning and Material Detection: Precise positioning of components is ensured by locating pins on the fixture, providing a stable foundation for the gluing process. The use of through-beam sensor technology automatically detects whether materials are correctly placed, ensuring the accuracy of the production process and preventing the occurrence of missing materials.

 

Automatic Gluing: The equipment automatically applies glue gluing, with precise control of the gluing amount through a screw valve, ensuring the uniformity of the glue application.

 

Stator Pressing and Detection: After moving the stator assembly to the pressing station, the equipment precisely presses the stator into the housing. A pressure curve detection system is used to ensure that the pressing process meets the process requirements and quality standards.

 

B.Stator Heating and Housing Pressing Machine

 

Temperature Monitoring and Rapid Heating: The machine is equipped with a built-in temperature sensor that monitors the product temperature in real-time, ensuring the precision and consistency of the heating process. The heating station is mounted on an up-and-down moving module, capable of heating the stator to the required temperature in just 3 seconds for rapid heating.

 

Pressing and Detection: Automated equipment is used to press the stator into the housing, and the pressing process is monitored through a pressure curve detection system to ensure the quality of the pressing.

 

Cooling: After the pressing is completed, to ensure a tight bond between the stator and the housing, a cooling process is applied to the finished product.

 

C.Bearing Pressing and Counter-Riveting Machine

 

Bearing Automatic Feeding: Bearings are automatically fed through a material tube, then pushed onto the conveyor belt by a separating push plate, and the material condition of the bearings is checked again using a through-beam sensor.

 

Pressing and Counter-Riveting Integrated: The bearing press mold is equipped with a riveting knife, capable of simultaneously completing the pressing and counter-riveting operations of the bearings, with a pressure curve detection mechanism ensuring the accuracy and consistency of the force applied.

 

Cleaning: The pressing station is equipped with a vacuum suction function to remove any debris or impurities that may be generated during the pressing process, ensuring the cleanliness of the pressing environment.

 

D.Oil Seal Pressing and Oiling Machine

 

Positioning & Detection: The positioning method using pins and through-beam sensors ensures that the seal and motor are in place, ensuring the accuracy and completeness of the materials.

 

Oil Seal Oiling: The inner circle of the oil seal is automatically coated with grease by the equipment, and the outer circle is coated with lubricating oil to ensure the lubrication and sealing of the oil seal.

 

CCD Vision Inspection System: It automatically inspects for issues such as missing seals, missing oil seals, incorrect orientation of oil seals, and missed oiling, ensuring that the product meets quality standards.

 

E.Connector Resistance Welding Machine

 

Positioning and Detection: The connectors to be welded are manually placed into the machine's dedicated jig and precisely positioned to ensure accurate placement before welding. Sensors are then used to automatically detect whether the connectors are correctly placed, preventing welding defects that may arise from their absence or incorrect placement.

 

Automatic Welding: The machine automatically transports the connectors to the welding station for precise resistance welding. To ensure consistent welding pressure, the process is equipped with a chiller and the welding fixture has a pressure monitoring function, working together to ensure the consistency of welding quality.

 

Welding Quality Inspection: To ensure the quality of the welding, we conduct inspections in the following ways: using cameras to detect any missed welds at the welding points; a pin pressure detection device to ensure good contact between the connector's pins and the circuit board for a stable weld; and testing the resistance value after welding to ensure the stability of the electrical connection.

 

Testing Machines of HONEST

 

A. Hermetic Seal Test Machine

 

Positioning and Testing: The machine ensures that the motor is properly placed using locating pins and sensor technology, providing a stable foundation for hermetic seal testing.

 

Multi-Position Testing Setup: To ensure testing efficiency, the sealing test station is set up with four positions, distributed across two machine racks, effectively increasing testing efficiency and accelerating the overall production process.

 

Independent Shock Absorption Mechanism: To reduce vibration and noise during testing, each test position is individually equipped with a shock absorption mechanism, which helps to improve the accuracy and reliability of the test results.

 

B. Marking & Plug Inspection Machine

 

Automated Marking and Inspection: The marking station automatically performs marking operations, including QR codes, clear codes, and logos. The laser marker is equipped with horizontal and vertical hand-operated lead screws and a scale for easy adjustment of the marking position between different products. After marking, the system will automatically perform a scanning inspection to ensure the accuracy and traceability of the marked content.

 

The Advantages of HONEST Brushless Motor Automated Production Line

 

1.Diverse Product Compatibility: Our production line boasts high compatibility, suitable for the automatic assembly and testing of a variety of motor models, including oil pump motors, gear shift motors, and clutch motors.

 

2.Combination of Manual and Automated Processes: The main conveyance system utilizes manual loading and unloading with the assistance of a belt conveyor, and each machine is equipped with a reject bin, ensuring flexibility in the production process and the stability and consistency of product quality.

 

3.Full-Process Traceable Production Monitoring: Every machine on the production line is equipped with a barcode scanner, which reads product production information through QR codes, facilitating the traceability of production data and analysis.

 

4.Easy Model Changeover: With high compatibility, changing models for production is convenient by simply replacing the fixtures, and adapting to different production requirements.

 

About HONEST

 

HONEST has achieved high efficiency and quality control in the production process through automation and intelligent technology. From precise material feeding and positioning to intelligent material detection, and from automated handling to pressing, every step reflects the pursuit of production quality and efficiency. The equipment not only enhances the level of automation in motor production but also ensures the consistency and reliability of products through precise detection equipment.

 

If you have any requirements for our brushless motor production line, please feel free to contact us at any time. We can provide you with customized service for your project as well as a preliminary quotation.