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Each part of our high speed brushless dc motor is perfectly manufactured. We, BG Motor have been putting the 'Quality First' as our basic tenet. From raw materials selection, design, to the final quality test, we always adhere to the highest standard in the international market to perform the whole procedure. Our designers are keen and intense in the aspect of observation and perception to the design. Thanks to that, our product can be highly praised as the artistic work. Besides that, we will carry out several rounds of strict quality tests before the product being shipped out.
BG Motor has made considerable efforts to implement the promotion of our brand reputation for getting larger amounts of orders from the high-end markets. As is known to all, BG Motor has already become a regional leader in this field while. At the same time, we are continuously strengthening our efforts at encroaching on the international market and our hard work has reaped a high payoff with our increased sales in the overseas markets.
At BG MOTOR, attention to details is the core value of our company. All products including high speed brushless dc motor are designed with uncompromised quality and craftsmanship. All services are rendered with consideration to the best interest of the customers.
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What is an air gap?
A simple way to define air gap is to say it is the air in the space between the stator and the rotor of the motor.
More specifically, we can have similar definitions for alternating current or AC motors and direct current or direct current motors.
In an AC motor, the air gap is the air space between the rotor core and the stator. On the other hand, it is said to be the space between the poles and the armature of a DC motor.
The flux gap is the distance between the high permeability material in the stator (stator "iron") and the corresponding high permeability material in the rotor (rotor "back iron"). This material is usually made from thin laminations of Fe-Si steel.
As we all know, in general, the flux gap should be as small as possible.
Note that the flux gap includes magnets. Rare earth magnets (magnetized or unmagnetized) have essentially the same permeability as air. Therefore, from the stator point of view, the magnets are indistinguishable from air and should be included as part of the flux gap.
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How does the air gap work?
To understand how air gaps work, first remember that electric motors and generators are rotating electrical machines.
This means that electric motors and generators work very similarly. The difference is that electric motors convert the supplied electrical energy into mechanical energy. Instead, generators take specific mechanical energy and convert it into electrical energy.
In both cases, the energy conversion process occurs when the stator and rotor work together to generate magnetic flux through their own copper windings. This is where the air gap comes into play.
A magnetic field is formed in the air gap, and one of the above-mentioned windings is responsible for generating the magnetic flux, which has to pass through the air gap twice for each pole of each phase of the motor.
Some of the key factors related to air gap operation are:
Magnetic force is inversely proportional to the square of the distance. As the air gap size increases, the magnetic attraction decreases and becomes more difficult to control.
Increasing the size of the air gap increases the magnetizing current, which represents the amount of current required to drive magnetic flux through the air gap.
The more poles a motor or generator has, the more times the flux must cross the air gap per revolution.
All these factors lead us to conclude that the smaller the air gap, the better. However, a smaller air gap means less separation between the moving parts of the rotor and the stator. This is why monitoring the air gap in motors and generators is critical, as the slightest variation in the alignment of the air gap with these characteristics can create operational problems in the machine.
The magnetic circuit consists of a soft iron ring, a copper winding (2A, 250 turns) represented by a green rectangle, and an air gap in the ring. Flux density (units of Tesla) is represented by the distance between the flux lines and the color, with red being the highest density and blue being the lowest. The flux density is clearly greatest in rings with small flux gaps. This ring also has the least amount of flux "leaking" into the surrounding air.
The reason for this difference is that the air gap increases the reluctance of the circuit. Reluctance is flux in a magnetic circuit, just like resistance is current in a circuit. Therefore, the magnetic flux in a circuit depends on the total reluctance and the applied magnetomotive force (number of turns times the current), just as the current depends on the total resistance in the circuit and the applied voltage.
Let's take a closer look at how the flux varies with the flux gap itself. We can do this by drawing a line across the flux gap and measuring the flux density at each point on the line.
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Doing this for flux gaps of 1 mm and 4 mm it is clear that the flux in the middle of each gap remains the same. It can also be seen that the flux in the 4 mm flux gap is four times smaller than the flux in the 1 mm flux gap. So to produce the same flux density in a 4 mm gap we need to quadruple the windings at the same current, or keep the same number of windings and quadruple the current. This concept can also be applied to electric motors and explains why engineers usually go to great lengths to keep the flux gap as small as possible.
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Influence of Flux Gap Size on Torque of Simple Motor
The torque produced by the motor depends on the flux density in the air gap, and as the size of the flux gap increases, the torque decreases gradually
From the above discussion it is clear that in general we want the flux gap to be physically as small as possible to increase the motor torque output, hence it is the motor constant. However, in addition to manufacturing tolerances, we also need to consider the thickness of the magnet. In general, if you make the rotor magnets longer, the flux density at their poles also increases. This will increase the torque output of the motor.
If you don't know much about the internal clearance of the brushless motor, you can contact our salesman, and they will give you a professional answer.
What is an air gap?
A simple way to define air gap is to say it is the air in the space between the stator and the rotor of the motor.
More specifically, we can have similar definitions for alternating current or AC motors and direct current or direct current motors.
In an AC motor, the air gap is the air space between the rotor core and the stator. On the other hand, it is said to be the space between the poles and the armature of a DC motor.
The flux gap is the distance between the high permeability material in the stator (stator "iron") and the corresponding high permeability material in the rotor (rotor "back iron"). This material is usually made from thin laminations of Fe-Si steel.
As we all know, in general, the flux gap should be as small as possible.
Note that the flux gap includes magnets. Rare earth magnets (magnetized or unmagnetized) have essentially the same permeability as air. Therefore, from the stator point of view, the magnets are indistinguishable from air and should be included as part of the flux gap.
#unit-i77vWdA7EErkBKP .ce-image_inner{justify-content:center;}#unit-i77vWdA7EErkBKP .ce-image{height:100%;width:100%;--image-effect:2;}
#module-ocfRA0Wwm81Ll{padding-top:1vw;padding-bottom:1vw;}
How does the air gap work?
To understand how air gaps work, first remember that electric motors and generators are rotating electrical machines.
This means that electric motors and generators work very similarly. The difference is that electric motors convert the supplied electrical energy into mechanical energy. Instead, generators take specific mechanical energy and convert it into electrical energy.
In both cases, the energy conversion process occurs when the stator and rotor work together to generate magnetic flux through their own copper windings. This is where the air gap comes into play.
A magnetic field is formed in the air gap, and one of the above-mentioned windings is responsible for generating the magnetic flux, which has to pass through the air gap twice for each pole of each phase of the motor.
Some of the key factors related to air gap operation are:
Magnetic force is inversely proportional to the square of the distance. As the air gap size increases, the magnetic attraction decreases and becomes more difficult to control.
Increasing the size of the air gap increases the magnetizing current, which represents the amount of current required to drive magnetic flux through the air gap.
The more poles a motor or generator has, the more times the flux must cross the air gap per revolution.
All these factors lead us to conclude that the smaller the air gap, the better. However, a smaller air gap means less separation between the moving parts of the rotor and the stator. This is why monitoring the air gap in motors and generators is critical, as the slightest variation in the alignment of the air gap with these characteristics can create operational problems in the machine.
The magnetic circuit consists of a soft iron ring, a copper winding (2A, 250 turns) represented by a green rectangle, and an air gap in the ring. Flux density (units of Tesla) is represented by the distance between the flux lines and the color, with red being the highest density and blue being the lowest. The flux density is clearly greatest in rings with small flux gaps. This ring also has the least amount of flux "leaking" into the surrounding air.
The reason for this difference is that the air gap increases the reluctance of the circuit. Reluctance is flux in a magnetic circuit, just like resistance is current in a circuit. Therefore, the magnetic flux in a circuit depends on the total reluctance and the applied magnetomotive force (number of turns times the current), just as the current depends on the total resistance in the circuit and the applied voltage.
Let's take a closer look at how the flux varies with the flux gap itself. We can do this by drawing a line across the flux gap and measuring the flux density at each point on the line.
#unit-Viz1JRttQScG3na .ce-image_inner{justify-content:center;}#unit-Viz1JRttQScG3na .ce-image{height:100%;width:100%;--image-effect:2;}
Doing this for flux gaps of 1 mm and 4 mm it is clear that the flux in the middle of each gap remains the same. It can also be seen that the flux in the 4 mm flux gap is four times smaller than the flux in the 1 mm flux gap. So to produce the same flux density in a 4 mm gap we need to quadruple the windings at the same current, or keep the same number of windings and quadruple the current. This concept can also be applied to electric motors and explains why engineers usually go to great lengths to keep the flux gap as small as possible.
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Influence of Flux Gap Size on Torque of Simple Motor
The torque produced by the motor depends on the flux density in the air gap, and as the size of the flux gap increases, the torque decreases gradually
From the above discussion it is clear that in general we want the flux gap to be physically as small as possible to increase the motor torque output, hence it is the motor constant. However, in addition to manufacturing tolerances, we also need to consider the thickness of the magnet. In general, if you make the rotor magnets longer, the flux density at their poles also increases. This will increase the torque output of the motor.
If you don't know much about the internal clearance of the brushless motor, you can contact our salesman, and they will give you a professional answer.
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Have you encountered the phenomenon that the surface of the motor is seriously hot after the motor runs for a period of time when the motor is in the sample test?
This article will answer you in great detail and give you some very useful solutions.
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Causes the motor to heat up
1.The ambient temperature is too high. If the ambient temperature exceeds 40 ℃, the motor temperature will rise.
2. The surrounding environment is seriously polluted by dust. Motors operating for a long time in this environment absorb a lot of dust, which blocks the gap between the coils at the end and the ventilation holes of the iron core (if the bearing leaks oil, the blockage is more serious), resulting in a greatly reduced air intake and overheating of the motor. .
3. The driven machinery fails (with friction or jamming), the stator and the rotor collide, the motor makes a metal impact sound, and even causes the motor to get stuck and does not rotate, causing the motor to over-current and heating, the temperature of the iron core rises rapidly, serious When the motor smokes, or even the coil burns.
4. Short circuit between cold air and hot air. For centrifugal fans, because the gap between the windshield of the end cover and the fan is too large, the low-pressure wind and the high-pressure wind are short-circuited, which reduces the air volume entering the motor and causes the motor to overheat.
5. The power supply voltage is too high. The motor operates within a 5~+10% change in the rated voltage, and the rated output can be kept unchanged. If the power supply voltage exceeds 10% of the rated voltage, the magnetic flux density of the iron core will increase sharply, and the motor will overheat due to the increase in iron loss.
6. The power supply is out of phase, and the motor winding or wiring is disconnected in one phase, so that the motor only works in two phases. If the power supply is out of phase, causing the single-phase operation of the motor, the windings of the motor will be rapidly heated and burned in a short time.
7. The cooler of the motor fails, or the air leakage is not strictly blocked, and the hot air directly leaks into the cold air area, which increases the air temperature of the motor population and causes the motor to overheat.
8. When the indoor exhaust system fails, the hot air discharged by the motor cannot be quickly discharged, and is immediately sucked in by the motor, causing the motor to overheat.
9. Motors with axial flow fans, if the fan rotates in the opposite direction, will also cause the motor to overheat. Excessive load. The windings are partially short-circuited or grounded, the motor is overheated locally in light cases, and the insulation is burned out in severe cases, emitting burnt smell or even smoke.
10. The external wiring of the motor is wrong, and there are two situations as follows: (1) The △ connection should be mistakenly connected to the Y connection, so that the current is very small at no-load, although the load can be driven at light load, but the current exceeds the rated value, so that The motor is hot. (2) The Y connection method should be mistakenly connected to the △ connection method, so that the current may be greater than the rated current at no-load, so that the temperature of the motor rises rapidly.
11. If the fluctuation of the power supply voltage is too large, the fluctuation range of the power supply voltage should be controlled between -5~10%, otherwise the load of the motor should be controlled. After overhaul, the number of turns of the coil is wrong or a certain pole, phase and group wiring are wrong.
12. After the overhaul, the wire section is smaller than the original section.
13. The stator and rotor iron cores are seriously dislocated. Although the no-load current is three-phase balanced, it is greater than the specified value.
14. The squirrel-cage rotor is broken or defective. The temperature of the iron core rises rapidly after the motor runs for 1~2h, and even exceeds the winding temperature. When it is heavily loaded or fully loaded, the stator current exceeds the rated value.
15. The welding point of the rotor winding of the wound motor is de-soldered, or the welding is not good during inspection, which causes the rotor to overheat and the speed and torque decrease significantly.
16. The motor winding is damp, or there is dust, oil, etc. attached to the winding, so that the insulation is reduced.
17. The motor starts too frequently in a short time.
#unit-Viz1JRttQScG3na .ce-image_inner{justify-content:center;}#unit-Viz1JRttQScG3na .ce-image{height:100%;width:100%;--image-effect:2;}#unit-Viz1JRttQScG3na{padding-top:1vw;}
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Troubleshooting methods:
1.If it is a new motor, the wiring should be checked first; if the wiring is ok, it should be determined whether the motor is overloaded.
2. If the motor runs normally for a period of time, first check whether the fan is normal.
3. If the heat dissipation is normal, the three-phase current should be checked to see if there is a phase loss. If there is a phase loss, the power supply should be cut off immediately to determine whether the winding is open circuit or there is a power supply problem.
4. If the power supply is normal, check whether the position of the stator and rotor is correct, and whether the mechanical transmission is stuck. The motor should be disassembled to check whether there are traces of sweeping on the iron core, find out the reason, and deal with it.
5. If there is no problem mechanically, measure the DC resistance of each phase of the winding to see if there is a short-circuit point, use a megohmmeter to check whether the winding is grounded, and clean and dry the motor.
6. For the squirrel cage rotor, check whether the rotor is broken or defective, and re-weld or replace the rotor.
7. For the winding rotor, check whether the DC resistance of the rotor winding is normal and whether the welding points are loose.
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Optimization measures
Often, we can improve the environment, optimize the working process of the motor, and install thermal protection devices to prevent the motor from overheating:
1.First, improve the operating environment of the motor. The ventilation and cooling conditions should be improved. If the environment is not easy to change, the motor with a higher heat resistance level should be replaced.
2. Optimize the motor startup and operation process to avoid frequent motor startup.
3. Adopt effective overheat protection device to avoid motor overheating and burn out, generally there are the following types:
(1) Use melt or air breaker as short-circuit protection device, and the protection characteristic curve is matched with the heating characteristic curve of the motor.
(2) Use thermal relays, etc. as the overload protection device of the motor, and the protection characteristic curve matches the heating characteristic curve of the motor.
(3) A temperature protection device is installed in the stator winding, and the circuit is automatically cut off when the motor is close to the maximum allowable temperature.
(4) A phase failure protection device is installed in the control circuit of the motor, and the power supply of the motor is cut off when the phase is disconnected.
(5) Install a low-voltage protection device in the control circuit, and cut off the power supply when the voltage is lower than a certain value. There may be other reasons for the heating of the motor, but we usually use the motor correctly in strict accordance with the operating procedures, maintain the motor correctly, make the surface of the motor clean, the current does not exceed the rated value, the vibration value is within the range, the running sound is normal, and the bearing is correct. Maintenance, etc., the service life of the motor will be extended.
If you don't know how to choose the motor that suits you, you can contact our sales staff, they will recommend the motor suitable for your product according to your product requirements
Have you encountered the phenomenon that the surface of the motor is seriously hot after the motor runs for a period of time when the motor is in the sample test?
This article will answer you in great detail and give you some very useful solutions.
#unit-i77vWdA7EErkBKP .ce-image_inner{justify-content:center;}#unit-i77vWdA7EErkBKP .ce-image{height:100%;width:100%;--image-effect:2;}
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Causes the motor to heat up
1.The ambient temperature is too high. If the ambient temperature exceeds 40 ℃, the motor temperature will rise.
2. The surrounding environment is seriously polluted by dust. Motors operating for a long time in this environment absorb a lot of dust, which blocks the gap between the coils at the end and the ventilation holes of the iron core (if the bearing leaks oil, the blockage is more serious), resulting in a greatly reduced air intake and overheating of the motor. .
3. The driven machinery fails (with friction or jamming), the stator and the rotor collide, the motor makes a metal impact sound, and even causes the motor to get stuck and does not rotate, causing the motor to over-current and heating, the temperature of the iron core rises rapidly, serious When the motor smokes, or even the coil burns.
4. Short circuit between cold air and hot air. For centrifugal fans, because the gap between the windshield of the end cover and the fan is too large, the low-pressure wind and the high-pressure wind are short-circuited, which reduces the air volume entering the motor and causes the motor to overheat.
5. The power supply voltage is too high. The motor operates within a 5~+10% change in the rated voltage, and the rated output can be kept unchanged. If the power supply voltage exceeds 10% of the rated voltage, the magnetic flux density of the iron core will increase sharply, and the motor will overheat due to the increase in iron loss.
6. The power supply is out of phase, and the motor winding or wiring is disconnected in one phase, so that the motor only works in two phases. If the power supply is out of phase, causing the single-phase operation of the motor, the windings of the motor will be rapidly heated and burned in a short time.
7. The cooler of the motor fails, or the air leakage is not strictly blocked, and the hot air directly leaks into the cold air area, which increases the air temperature of the motor population and causes the motor to overheat.
8. When the indoor exhaust system fails, the hot air discharged by the motor cannot be quickly discharged, and is immediately sucked in by the motor, causing the motor to overheat.
9. Motors with axial flow fans, if the fan rotates in the opposite direction, will also cause the motor to overheat. Excessive load. The windings are partially short-circuited or grounded, the motor is overheated locally in light cases, and the insulation is burned out in severe cases, emitting burnt smell or even smoke.
10. The external wiring of the motor is wrong, and there are two situations as follows: (1) The △ connection should be mistakenly connected to the Y connection, so that the current is very small at no-load, although the load can be driven at light load, but the current exceeds the rated value, so that The motor is hot. (2) The Y connection method should be mistakenly connected to the △ connection method, so that the current may be greater than the rated current at no-load, so that the temperature of the motor rises rapidly.
11. If the fluctuation of the power supply voltage is too large, the fluctuation range of the power supply voltage should be controlled between -5~10%, otherwise the load of the motor should be controlled. After overhaul, the number of turns of the coil is wrong or a certain pole, phase and group wiring are wrong.
12. After the overhaul, the wire section is smaller than the original section.
13. The stator and rotor iron cores are seriously dislocated. Although the no-load current is three-phase balanced, it is greater than the specified value.
14. The squirrel-cage rotor is broken or defective. The temperature of the iron core rises rapidly after the motor runs for 1~2h, and even exceeds the winding temperature. When it is heavily loaded or fully loaded, the stator current exceeds the rated value.
15. The welding point of the rotor winding of the wound motor is de-soldered, or the welding is not good during inspection, which causes the rotor to overheat and the speed and torque decrease significantly.
16. The motor winding is damp, or there is dust, oil, etc. attached to the winding, so that the insulation is reduced.
17. The motor starts too frequently in a short time.
#unit-Viz1JRttQScG3na .ce-image_inner{justify-content:center;}#unit-Viz1JRttQScG3na .ce-image{height:100%;width:100%;--image-effect:2;}#unit-Viz1JRttQScG3na{padding-top:1vw;}
#module-9NS7yxvJ5gLiO{padding-top:1vw;padding-bottom:1vw;}
Troubleshooting methods:
1.If it is a new motor, the wiring should be checked first; if the wiring is ok, it should be determined whether the motor is overloaded.
2. If the motor runs normally for a period of time, first check whether the fan is normal.
3. If the heat dissipation is normal, the three-phase current should be checked to see if there is a phase loss. If there is a phase loss, the power supply should be cut off immediately to determine whether the winding is open circuit or there is a power supply problem.
4. If the power supply is normal, check whether the position of the stator and rotor is correct, and whether the mechanical transmission is stuck. The motor should be disassembled to check whether there are traces of sweeping on the iron core, find out the reason, and deal with it.
5. If there is no problem mechanically, measure the DC resistance of each phase of the winding to see if there is a short-circuit point, use a megohmmeter to check whether the winding is grounded, and clean and dry the motor.
6. For the squirrel cage rotor, check whether the rotor is broken or defective, and re-weld or replace the rotor.
7. For the winding rotor, check whether the DC resistance of the rotor winding is normal and whether the welding points are loose.
#unit-eUW6ULjPoj9w0d9{padding-top:1vw;}
Optimization measures
Often, we can improve the environment, optimize the working process of the motor, and install thermal protection devices to prevent the motor from overheating:
1.First, improve the operating environment of the motor. The ventilation and cooling conditions should be improved. If the environment is not easy to change, the motor with a higher heat resistance level should be replaced.
2. Optimize the motor startup and operation process to avoid frequent motor startup.
3. Adopt effective overheat protection device to avoid motor overheating and burn out, generally there are the following types:
(1) Use melt or air breaker as short-circuit protection device, and the protection characteristic curve is matched with the heating characteristic curve of the motor.
(2) Use thermal relays, etc. as the overload protection device of the motor, and the protection characteristic curve matches the heating characteristic curve of the motor.
(3) A temperature protection device is installed in the stator winding, and the circuit is automatically cut off when the motor is close to the maximum allowable temperature.
(4) A phase failure protection device is installed in the control circuit of the motor, and the power supply of the motor is cut off when the phase is disconnected.
(5) Install a low-voltage protection device in the control circuit, and cut off the power supply when the voltage is lower than a certain value. There may be other reasons for the heating of the motor, but we usually use the motor correctly in strict accordance with the operating procedures, maintain the motor correctly, make the surface of the motor clean, the current does not exceed the rated value, the vibration value is within the range, the running sound is normal, and the bearing is correct. Maintenance, etc., the service life of the motor will be extended.
If you don't know how to choose the motor that suits you, you can contact our sales staff, they will recommend the motor suitable for your product according to your product requirements
#module-EtmmzqA27d0bo{padding-top:1vw;padding-bottom:1vw;}
Neodymium magnets can be called NdFeB magnets, which is a general term for strong magnets. The chemical formula is Nd2Fe14B, and it is one of the artificial permanent magnet materials with the strongest magnetic force so far. The material grade of NdFeB magnets is N35-N52, which can be processed into different shapes according to specific requirements, such as round, square, punching, magnetic tile, magnetic rod, convex or trapezoidal, etc. Therefore, how to distinguish between bonded NdFeB and sintered NdFeB?
In fact, both magnets are NdFeB. These two magnets are distinguished according to their production process. Bonded NdFeB magnets are formed by injection molding, and sintered NdFeB magnets are formed by high temperature heating
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1. Production process of bonded NdFeB magnets
Bonded NdFeB magnets are formed by injection molding. The density is lower than that of sintered NdFeB because it contains a resin matrix, and the density varies according to the content of the resin matrix. However, sintered NdFeB magnets are heated at high temperature through a complicated process and do not contain non-magnetic resin components. Therefore, the performance of sintered NdFeB is higher than that of bonded NdFeB.
2. Production process of sintered NdFeB magnets
Sintered NdFeB magnets are anisotropic magnets produced by powder sintering. Generally, only blanks can be produced by sintering, and magnets of various shapes need to be mechanically processed (such as wire cutting, slicing, grinding, etc.). Sintered NdFeB is a hard and brittle material that is difficult to process, so it has large losses during processing, high cost, poor dimensional accuracy, poor corrosion resistance, and the surface needs electroplating, but the advantage is high performance, which has reached more than 50M
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To sum up, the magnetic properties of bonded NdFeB magnets are relatively low, isotropic bonded magnets are usually below 10M, while anisotropic bonded magnets can reach about 16M. However, injection-molded NdFeB magnets also have their irreplaceable advantages. For example, the effective utilization rate is relatively high; the performance can be adjusted according to the needs of different products; the injection-molded magnets have high resistivity, which can effectively reduce eddy current loss and motor heating when used in the field of high-speed rotors; the sintering process is not suitable for molding complex shapes and structures products, and injection molding can easily solve this problem.
Of course, the different materials of NdFeB magnets are recommended according to the different scenarios of customers. If you are not very clear about the magnetic materials, you can contact the customer service of our official website at any time, and they will contact and recommend to you professionally.
Neodymium magnets can be called NdFeB magnets, which is a general term for strong magnets. The chemical formula is Nd2Fe14B, and it is one of the artificial permanent magnet materials with the strongest magnetic force so far. The material grade of NdFeB magnets is N35-N52, which can be processed into different shapes according to specific requirements, such as round, square, punching, magnetic tile, magnetic rod, convex or trapezoidal, etc. Therefore, how to distinguish between bonded NdFeB and sintered NdFeB?
In fact, both magnets are NdFeB. These two magnets are distinguished according to their production process. Bonded NdFeB magnets are formed by injection molding, and sintered NdFeB magnets are formed by high temperature heating
#unit-LNF20yv6U7Y5Aig .ce-image_inner{justify-content:center;}#unit-LNF20yv6U7Y5Aig .ce-image{height:100%;width:100%;--image-effect:2;}
1. Production process of bonded NdFeB magnets
Bonded NdFeB magnets are formed by injection molding. The density is lower than that of sintered NdFeB because it contains a resin matrix, and the density varies according to the content of the resin matrix. However, sintered NdFeB magnets are heated at high temperature through a complicated process and do not contain non-magnetic resin components. Therefore, the performance of sintered NdFeB is higher than that of bonded NdFeB.
2. Production process of sintered NdFeB magnets
Sintered NdFeB magnets are anisotropic magnets produced by powder sintering. Generally, only blanks can be produced by sintering, and magnets of various shapes need to be mechanically processed (such as wire cutting, slicing, grinding, etc.). Sintered NdFeB is a hard and brittle material that is difficult to process, so it has large losses during processing, high cost, poor dimensional accuracy, poor corrosion resistance, and the surface needs electroplating, but the advantage is high performance, which has reached more than 50M
#unit-i77vWdA7EErkBKP .ce-image_inner{justify-content:center;}#unit-i77vWdA7EErkBKP .ce-image{height:100%;width:100%;--image-effect:2;}
To sum up, the magnetic properties of bonded NdFeB magnets are relatively low, isotropic bonded magnets are usually below 10M, while anisotropic bonded magnets can reach about 16M. However, injection-molded NdFeB magnets also have their irreplaceable advantages. For example, the effective utilization rate is relatively high; the performance can be adjusted according to the needs of different products; the injection-molded magnets have high resistivity, which can effectively reduce eddy current loss and motor heating when used in the field of high-speed rotors; the sintering process is not suitable for molding complex shapes and structures products, and injection molding can easily solve this problem.
Of course, the different materials of NdFeB magnets are recommended according to the different scenarios of customers. If you are not very clear about the magnetic materials, you can contact the customer service of our official website at any time, and they will contact and recommend to you professionally.
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The performance of motor energy consumption is mainly in the following aspects
1.First, the motor load rate is low.
Due to the improper selection of the motor, excessive surplus or changes in the production process, the actual working load of the motor is far less than the rated load, and the motor that accounts for about 30% to 40% of the installed capacity runs under the rated load of 30% to 50%. Efficiency is too low.
2.Second, the power supply voltage is asymmetric or the voltage is too low.
Due to the unbalance of the single-phase load of the three-phase four-wire low-voltage power supply system, the three-phase voltage of the motor is asymmetrical, and the motor generates negative sequence torque. Losses in the operation of large motors. In addition, the grid voltage is low for a long time, which makes the motor current in normal operation too large, so the loss increases. The greater the three-phase voltage asymmetry, the lower the voltage, the greater the loss.
3.The third is that the old and old (obsolete) motors are still in use.
These motors use class E insulation, are bulky, have poor starting performance, and are inefficient. Although it has undergone years of renovation, it is still in use in many places.
4.Fourth, poor maintenance management.
Some units do not maintain the motors and equipment as required, and allow them to run for a long time, which makes the loss continue to increase.
Therefore, in view of these energy consumption performance, it is worth studying which energy saving scheme to choose.
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There are roughly seven types of motor energy-saving solutions
1. Select energy-saving motor
Compared with ordinary motors, the high-efficiency motor optimizes the overall design, selects high-quality copper windings and silicon steel sheets, reduces various losses, reduces losses by 20%~30%, and improves efficiency by 2%~7%; payback period Usually 1-2 years, some months. In comparison, the high-efficiency motor is 0.413% more efficient than the J02 series motor. Therefore, it is imperative to replace the old electric motors with high-efficiency electric motors.
2. Appropriate selection of motor capacity to achieve energy saving
The state has made the following regulations for the three operating areas of three-phase asynchronous motors: the economic operation area is between 70% and 100% of the load rate; the general operation area is between 40% and 70% of the load rate; the load rate is 40% The following are non-economic operating areas. Improper selection of motor capacity will undoubtedly result in waste of electric energy. Therefore, using a suitable motor to improve the power factor and load rate can reduce power loss and save energy.
3. Use magnetic slot wedge instead of original slot wedge
The magnetic slot wedge mainly reduces the no-load iron loss in the asynchronous motor. The no-load additional iron loss is generated in the stator and rotor iron core by the harmonic magnetic flux caused by the cogging effect in the motor. The high-frequency additional iron loss induced by the stator and rotor in the iron core is called pulse vibration loss. In addition, the teeth of the stator and rotor are sometimes aligned and sometimes misaligned, and the magnetic flux of the tooth cluster on the tooth surface fluctuates, which can induce eddy currents in the tooth surface line layer, resulting in surface loss. Pulse vibration loss and surface loss are collectively called high-frequency additional losses, which account for 70% to 90% of motor stray losses, and the other 10% to 30% are called load additional losses, which are generated by leakage magnetic flux. Although the use of magnetic slot wedges will reduce the starting torque by 10% to 20%, the iron loss of the motor using magnetic slot wedges can be reduced by 60k compared to the motor using ordinary slot wedges, and it is very suitable for no-load or light-load starting motor transformation .
#unit-1e5O7TXue71GApX .ce-image_inner{justify-content:center;}#unit-1e5O7TXue71GApX .ce-image{height:100%;width:100%;--image-effect:2;}#unit-1e5O7TXue71GApX{padding-bottom:1vw;padding-top:1vw;}
4. Adopt Y/△ automatic conversion device
In order to solve the waste of electric energy when the equipment is lightly loaded, on the premise of not replacing the motor, a Y/△ automatic conversion device can be used to achieve the purpose of saving electricity. Because in the three-phase AC power grid, the voltage obtained by the different connection of the load is different, so the energy absorbed from the power grid is also different.
5. Motor power factor reactive power compensation
Improving power factor and reducing power loss are the main purposes of reactive power compensation. The power factor is equal to the ratio of active power to apparent power. Usually, a low power factor will cause excessive current. For a given load, when the supply voltage is constant, the lower the power factor, the greater the current. Therefore, the power factor is as high as possible to save electric energy.
6. Frequency conversion speed regulation
Most of the loads of fans and pumps are selected according to the demand for full-load work. In practical applications, most of the time is not in a full-load working state. Since it is difficult to adjust the speed of AC motors, windshields, return valves, or start and stop times are often used to adjust the air volume or flow. At the same time, it is difficult for large motors to frequently start and stop under the power frequency state, and the power shock is large, which will inevitably cause power loss and Current impact when switching on and off. It is the most scientific control method to directly control the load of fans and pumps with the frequency converter. When the motor runs at 80% of the rated speed, the energy saving efficiency is close to 40%. At the same time, closed-loop constant pressure control can also be realized, and the energy saving efficiency will be further improved. . Because the frequency converter can realize the soft stop and soft start of large motors, it avoids the voltage shock when starting, reduces the failure rate of the motor, prolongs the service life, and also reduces the capacity requirements and reactive power loss of the power grid.
7. Liquid speed regulation of winding motor
The liquid resistance speed control technology is developed on the basis of the traditional product liquid resistance starter. The purpose of stepless speed regulation is still achieved by changing the distance between the plates to adjust the size of the resistance. This makes it have good starting performance at the same time. It is powered on for a long time, which brings about the problem of heating and heating. Due to the unique structure and reasonable heat exchange system, its working temperature is limited to a reasonable temperature. The liquid resistance speed regulation technology for winding motors has been rapidly popularized due to its advantages of reliable operation, convenient installation, large energy saving, easy maintenance and low investment. For some speed regulation accuracy, the requirements for speed regulation are not high and the speed regulation range is not wide. , and infrequent speed regulation of wound motors, such as large and medium wound asynchronous motors of fans, pumps and other equipment, the use of liquid speed regulation effect is remarkable.
The performance of motor energy consumption is mainly in the following aspects
1.First, the motor load rate is low.
Due to the improper selection of the motor, excessive surplus or changes in the production process, the actual working load of the motor is far less than the rated load, and the motor that accounts for about 30% to 40% of the installed capacity runs under the rated load of 30% to 50%. Efficiency is too low.
2.Second, the power supply voltage is asymmetric or the voltage is too low.
Due to the unbalance of the single-phase load of the three-phase four-wire low-voltage power supply system, the three-phase voltage of the motor is asymmetrical, and the motor generates negative sequence torque. Losses in the operation of large motors. In addition, the grid voltage is low for a long time, which makes the motor current in normal operation too large, so the loss increases. The greater the three-phase voltage asymmetry, the lower the voltage, the greater the loss.
3.The third is that the old and old (obsolete) motors are still in use.
These motors use class E insulation, are bulky, have poor starting performance, and are inefficient. Although it has undergone years of renovation, it is still in use in many places.
4.Fourth, poor maintenance management.
Some units do not maintain the motors and equipment as required, and allow them to run for a long time, which makes the loss continue to increase.
Therefore, in view of these energy consumption performance, it is worth studying which energy saving scheme to choose.
#unit-i77vWdA7EErkBKP .ce-image_inner{justify-content:center;}#unit-i77vWdA7EErkBKP .ce-image{height:100%;width:100%;--image-effect:2;}#unit-i77vWdA7EErkBKP{padding-top:1vw;padding-bottom:1vw;}
There are roughly seven types of motor energy-saving solutions
1. Select energy-saving motor
Compared with ordinary motors, the high-efficiency motor optimizes the overall design, selects high-quality copper windings and silicon steel sheets, reduces various losses, reduces losses by 20%~30%, and improves efficiency by 2%~7%; payback period Usually 1-2 years, some months. In comparison, the high-efficiency motor is 0.413% more efficient than the J02 series motor. Therefore, it is imperative to replace the old electric motors with high-efficiency electric motors.
2. Appropriate selection of motor capacity to achieve energy saving
The state has made the following regulations for the three operating areas of three-phase asynchronous motors: the economic operation area is between 70% and 100% of the load rate; the general operation area is between 40% and 70% of the load rate; the load rate is 40% The following are non-economic operating areas. Improper selection of motor capacity will undoubtedly result in waste of electric energy. Therefore, using a suitable motor to improve the power factor and load rate can reduce power loss and save energy.
3. Use magnetic slot wedge instead of original slot wedge
The magnetic slot wedge mainly reduces the no-load iron loss in the asynchronous motor. The no-load additional iron loss is generated in the stator and rotor iron core by the harmonic magnetic flux caused by the cogging effect in the motor. The high-frequency additional iron loss induced by the stator and rotor in the iron core is called pulse vibration loss. In addition, the teeth of the stator and rotor are sometimes aligned and sometimes misaligned, and the magnetic flux of the tooth cluster on the tooth surface fluctuates, which can induce eddy currents in the tooth surface line layer, resulting in surface loss. Pulse vibration loss and surface loss are collectively called high-frequency additional losses, which account for 70% to 90% of motor stray losses, and the other 10% to 30% are called load additional losses, which are generated by leakage magnetic flux. Although the use of magnetic slot wedges will reduce the starting torque by 10% to 20%, the iron loss of the motor using magnetic slot wedges can be reduced by 60k compared to the motor using ordinary slot wedges, and it is very suitable for no-load or light-load starting motor transformation .
#unit-1e5O7TXue71GApX .ce-image_inner{justify-content:center;}#unit-1e5O7TXue71GApX .ce-image{height:100%;width:100%;--image-effect:2;}#unit-1e5O7TXue71GApX{padding-bottom:1vw;padding-top:1vw;}
4. Adopt Y/△ automatic conversion device
In order to solve the waste of electric energy when the equipment is lightly loaded, on the premise of not replacing the motor, a Y/△ automatic conversion device can be used to achieve the purpose of saving electricity. Because in the three-phase AC power grid, the voltage obtained by the different connection of the load is different, so the energy absorbed from the power grid is also different.
5. Motor power factor reactive power compensation
Improving power factor and reducing power loss are the main purposes of reactive power compensation. The power factor is equal to the ratio of active power to apparent power. Usually, a low power factor will cause excessive current. For a given load, when the supply voltage is constant, the lower the power factor, the greater the current. Therefore, the power factor is as high as possible to save electric energy.
6. Frequency conversion speed regulation
Most of the loads of fans and pumps are selected according to the demand for full-load work. In practical applications, most of the time is not in a full-load working state. Since it is difficult to adjust the speed of AC motors, windshields, return valves, or start and stop times are often used to adjust the air volume or flow. At the same time, it is difficult for large motors to frequently start and stop under the power frequency state, and the power shock is large, which will inevitably cause power loss and Current impact when switching on and off. It is the most scientific control method to directly control the load of fans and pumps with the frequency converter. When the motor runs at 80% of the rated speed, the energy saving efficiency is close to 40%. At the same time, closed-loop constant pressure control can also be realized, and the energy saving efficiency will be further improved. . Because the frequency converter can realize the soft stop and soft start of large motors, it avoids the voltage shock when starting, reduces the failure rate of the motor, prolongs the service life, and also reduces the capacity requirements and reactive power loss of the power grid.
7. Liquid speed regulation of winding motor
The liquid resistance speed control technology is developed on the basis of the traditional product liquid resistance starter. The purpose of stepless speed regulation is still achieved by changing the distance between the plates to adjust the size of the resistance. This makes it have good starting performance at the same time. It is powered on for a long time, which brings about the problem of heating and heating. Due to the unique structure and reasonable heat exchange system, its working temperature is limited to a reasonable temperature. The liquid resistance speed regulation technology for winding motors has been rapidly popularized due to its advantages of reliable operation, convenient installation, large energy saving, easy maintenance and low investment. For some speed regulation accuracy, the requirements for speed regulation are not high and the speed regulation range is not wide. , and infrequent speed regulation of wound motors, such as large and medium wound asynchronous motors of fans, pumps and other equipment, the use of liquid speed regulation effect is remarkable.
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