You may have seen several kinds of motors, your razor, the washing machine, the fridge, just to name a few of their applications in life. But have you wondered how these motors are made? Here in this post, we’ll show you the common micro-motor technology of how a micro-motor is made from the beginning to the end.
Process 1: punching
The manufacturing technology of punching is closely related to the labor productivity of motor factory. Cutting and punching methods can be used for sheet production.
Cutting refers to wire cutting method, which can not only ensure the precision, but also shorten the production cycle of the motor. There are 4 kinds of punching methods: single-pattern punch, double-pattern punch, multiple-pattern punch and high speed punch.
Process 2: iron core making
There are various types of iron core in structures and shapes, resulting different manufacturing methods. Generally, the manufacturing methods can be summarized as: riveting, welding, bonding, dipping, sulfur and self-buckling.
- Riveting: fasten the metal sheets with rivets. This manual method is extremely inefficient.
- Welding: multiple sheets are stacked and pressed and then welded by arc welding. This method is good because it has high production efficiency and easy operation.
- Bonding: glue the sheets, then dry and laminate them. This manual method is suitable for small-scale production.
- Dipping: the sheet are laminated, and immersed with epoxy coatings. The method has good effects with saving labors and materials.
- Sulfur curing: the laminated sheets are cured with sulfur. This method costs little, is highly efficient, and produces lower noise, which is very suitable for mass production.
- Self-buckling: in the stamping process, the stator and rotor stamping sheets are automatically buckled and riveted. It’s necessary for scale economic production, indicating the future of overlapping.
Process 3: machining
There are various micro-motors with different structures. The machined parts are mainly the casing, the end cap shaft assembly, the stator assembly, the brush box, the commutator, the magnetic steel and various supporting structures.
Process 4: winding and welding
The winding is composed of coil winding, weaving and typing-in. Welding includes tin brazing, fusion welding, transition welding and pressure welding.
- Tin brazing: soldering iron is the most common. But it easily creates virtual welding that affects the quality.
- Welding: fuse the joint. It’s characterized by high flame temperature, small and concentrated temperature zone.
- Transition welding: it’s used for the connection between the motor lead cable and the armature winding. The purpose of the transition welding is to avoid the mess of the motor leads during the impregnation coating and the hardening during baking.
- Pressure welding: weld the lead wire in the slots. It’s usually used for armature windings of DC motor. The process is based on heating and the pressure is auxiliary.
Process 5: insulation treatment
Insulation is an important guarantee for the reliable operation of motor. Fusion, immersion, dipping and filling are the main aspects of insulation treatment.
- Fusion: uniformly adsorb the epoxy powder on the motor core by static electricity, and heat the powder, making it melt to form an insulating layer.
- Immersion: make the insulating coating immerse into the interior of the insulating material, between the wire turns and the iron core slot wall to form a film, so as to improve the heat resistance, moisture resistance and insulation strength.
- Dipping: penetrate the paint into the inner winding by gravity of the paint itself. It’s more usually seen in mass production.
- Injecting: inject the glue into the armature winding and heat it to form an integral. In this way, the armature winding will be firm, insulation reliable and great resistance to moisture, salty fog and mildew.
Process 6: surface treatment
Surface treatment is often used to prevent corrosion, protect decoration or meet certain special requirements for surface parts. The steam blackening treatment is one of surface treatment methods that is seeing a rapid growth in recent years.
To do it properly, the surface needs to be cleaned before the blackening, with 54 to 70 degrees steam at a saturated flow and pressure. Practical application shows that the process is mature, labor-saving and energy-saving.
This concludes what we have for today. If you have any questions, please feel free to contact us or leave a comment. We’d be glad to hear from you.