ASLONG 12mm N20 Series DC Motor: Case Study of Problem Addressing and Application Optimization

I. Problem Identification

II. Problem Analysis

1. Noise Issue: Upon analysis, it was found that the noise mainly originates from electromagnetic noise and mechanical vibrations within the motor. Electromagnetic noise tends to be more pronounced under high - load or high - speed conditions. Mechanical vibrations could be related to factors such as assembly precision, bearing quality, and rotor balance of the motor.
2. Starting Current Issue: The higher starting current is likely due to the motor's start - up characteristics. When starting, the motor needs to overcome significant static friction and load inertia, resulting in an elevated starting current. This can cause voltage fluctuations in the power supply or even lead to failures of other electrical components in equipment with limited power - supply capacity or sensitivity to current surges.
3. Low - Speed Stability Issue: Stability at low speeds is influenced by several factors, including the control accuracy and load variations of the motor as well as torque fluctuations within the motor itself. If the control system's performance is not optimized or the load changes significantly, the motor may experience speed fluctuations or even stalling at low speeds.

III. Solutions

1. Noise Reduction Measures
   • Electromagnetic Noise Optimization: The design of the stator winding of the motor has been improved, using higher - quality insulating materials and winding techniques to reduce the generation of electromagnetic noise. Additionally, the magnetic circuit structure of the motor has been optimized to minimize magnetic damping and saturation, thereby lowering electromagnetic noise.
   • Mechanical Vibration Optimization: The precision of motor assembly has been enhanced, utilizing more advanced manufacturing and assembly processes to ensure that all components are tightly matched and operate smoothly. High - quality bearings have been selected to improve the rotational precision and stability of the bearings, reducing mechanical vibrations caused by bearing quality issues. Rotor dynamic balancing has been implemented to ensure good balance of the rotor during high - speed rotation, minimizing mechanical vibrations.
2. Starting Current Optimization Measures
   • Optimizing Start - Up Control Strategy: A soft - start control technology has been adopted, which gradually increases the voltage or current applied to the motor during start - up, enabling the motor to transition smoothly from a stationary state to normal operation and effectively reducing the starting current. PWM (Pulse - Width Modulation) technology or progressive start - up circuits can be used to achieve soft - start control.
   • Adding Start - Up Auxiliary Devices: During the motor start - up phase, start - up auxiliary devices such as start - up capacitors or start - up resistors have been introduced to improve the start - up performance of the motor and reduce the starting current. Start - up capacitors can provide additional phase shift and energy during motor start - up, making it easier to start; start - up resistors can limit the size of the starting current, preventing excessive current from impacting the motor and power supply.
3. Low - Speed Stability Optimization Measures
   • Improving Control Algorithms: More advanced motor control algorithms, such as vector control or direct torque control, have been implemented to enhance the control accuracy and dynamic response performance of the motor at low - speed operation. These control algorithms can precisely regulate the torque and speed of the motor based on its real - time operating conditions, ensuring stable operation at low speeds.
   • Optimizing Load Matching: The matching relationship between the motor and the load has been rationally designed and optimized to ensure that load variations remain within the motor's capacity. The impact of load changes on the low - speed stability of the motor can be minimized by adjusting the mechanical transmission ratio of the load, increasing the load's inertia, or using buffer devices.
   • Enhancing Motor Performance: The manufacturing process and material quality of the motor have been further improved to reduce torque fluctuations within the motor. For example, higher - quality permanent - magnet materials have been used to enhance the stability of the motor's magnetic performance; the rotor structure of the motor has been optimized to reduce magnetic imbalance in the rotor; and more precise manufacturing processes have been employed to improve the precision and assembly quality of the motor's components, thereby enhancing the stability and reliability of the motor at low - speed operation.

IV. Implementation Results and Verification

1. Noise Reduction: Under high - load and high - speed operating conditions, the noise level of the motor has been significantly reduced as electromagnetic and mechanical vibrations have been effectively suppressed. Through sound - level meter measurements, the motor's noise has been reduced by approximately [X] dB (decibels), reaching an industry - advanced level and significantly improving the operating environment and user experience of the equipment.
2. Starting Current Optimization: After adopting soft - start control strategies and introducing start - up auxiliary devices, the starting current of the motor has been effectively controlled. The peak starting current has been reduced by about [Y]%, and power - supply voltage fluctuations have been significantly minimized, avoiding faults in electrical components caused by excessive starting currents and enhancing the reliability and stability of the equipment.
3. Low - Speed Stability Improvement: Stability at low - speed operation has been significantly enhanced through improvements in control algorithms, optimization of load matching, and enhancements in motor performance. The speed fluctuation range has been narrowed to within ±[Z] rpm (revolutions per minute), achieving stable low - speed operation that meets the stringent requirements of equipment for precision operations and low - speed control.

V. Conclusion and Outlook