JGB37-545B DC Motor: Problem Identification and Solutions

I. Background

(1) Problem Description

1. Noise Issue: During operation, the motor generated relatively high noise levels, especially under high load, which affected the working environment in the factory workshop.
2. Torque Fluctuation: The motor experienced unstable torque output during startup and shutdown, causing the equipment to run unevenly and affecting production efficiency and product quality.
3. Poor Heat Dissipation: After prolonged operation, the motor overheated, leading to performance degradation and even thermal protection shutdowns, which interrupted the continuous operation of the equipment.

II. Problem Analysis

1. Noise Issue: The noise primarily originated from the meshing of gears inside the motor and vibrations of the motor housing. Under high load, the frequent gear meshing increased the noise level.
2. Torque Fluctuation: The unstable torque was likely due to an imprecise control algorithm, causing significant current fluctuations during startup and shutdown, which in turn affected torque output.
3. Poor Heat Dissipation: The motor's heat dissipation design was insufficient, and the heat generated during prolonged operation could not be dissipated promptly, leading to temperature increases.

III. Solutions

(1) Noise Optimization

1. Improve Gear Design: Replace spur gears with high-precision helical gears to optimize the gear meshing angle and reduce noise during meshing.
2. Add Sound-Insulating Materials: Incorporate sound-insulating materials, such as rubber pads or sound-absorbing sponges, inside the motor housing to absorb noise generated during operation.
3. Optimize Motor Installation: Ensure that the motor is securely fastened during installation to reduce housing vibrations and thereby lower noise levels.

(2) Enhancing Torque Stability

1. Optimize Control Algorithms: Implement closed-loop control algorithms to monitor the motor's current and torque output in real-time and automatically adjust operating parameters according to load changes to ensure stable torque output.
2. Add Torque Compensation Module: Integrate a torque compensation module into the motor control system to dynamically compensate for torque output through software algorithms, reducing torque fluctuations during startup and shutdown.

(3) Heat Dissipation Optimization

1. Add Heat Sinks: Install heat sinks on the motor housing to increase the surface area for heat dissipation and improve cooling efficiency.
2. Optimize Internal Structure: Redesign the air flow channels inside the motor to add ventilation holes, ensuring effective heat dissipation during operation.
3. Use Thermal Conductive Materials: Apply thermal conductive silicone to key components inside the motor to quickly transfer heat to the housing, further enhancing cooling performance.

IV. Implementation Results

1. Noise Reduction: Operating noise was reduced from 45 decibels to 35 decibels, significantly improving the working environment in the workshop.
2. Torque Stability: Torque output stability increased by 30%, resulting in smoother equipment operation and improved product quality.
3. Heat Dissipation Improvement: The motor's operating temperature decreased by 20%, eliminating thermal protection shutdowns and significantly enhancing the equipment's continuous operation capability.

V. Conclusion