Minimum modification, maximum performance

In the industrial world, many engineers are challenged to improve the performance of existing equipment, reduce operating noise, extend service life, or adapt to new tasks. In the absence of reopening the mold, changing the mechanical structure, and redesigning the drivetrain, the question naturally focused on the motor: Can the overall performance of the equipment be greatly improved by simply replacing the motor? The answer is yes, BG motors offer a range of customized solutions

Upgrade the high-efficiency electromagnetic structure

The electromagnetic structure of the motor plays a decisive role in its performance. BG motors use advanced electromagnetic design techniques to optimize the magnetic flux density and magnetic circuit distribution of the motor to improve the efficiency and output torque of the motor. For example, in some industrial equipment with high efficiency requirements, BG motors use high-performance magnetic materials, such as neodymium-iron-boron permanent magnets, with unique pole shapes and winding designs, to reduce hysteresis loss and eddy current loss, so that the motor can output greater torque at the same input power, thereby improving the overall operating efficiency of the equipment. This efficient electromagnetic structure is not only suitable for the design of new equipment, but also for the motor upgrade of existing equipment. By replacing the customized electromagnetic structure with BG motors, the equipment can achieve a significant increase in performance without changing other components.

Practical application case: The automatic film sealing equipment of a food packaging machinery factory has an operating efficiency of only 65%, and the sealing film is often misaligned due to insufficient power during high-speed operation. Since the equipment frame and transmission gearbox are fixed, it is not possible to adjust the mechanical structure. BG customized a high-efficiency electromagnetic structure motor for it, keeping the installation size consistent with the original motor, and improving the motor efficiency to 82% by optimizing winding parameters and magnetic circuit design. After the retrofit, the equipment can run continuously for 12 hours without failure, the sealing pass rate has increased from 89% to 99%, and the daily production capacity has increased by 15%.

Added encoder closed-loop feedback

For more precise motion control, BG motors offer solutions to increase encoder closed-loop feedback. The encoder acts as a sensor that can accurately measure the position and speed of the motor shaft, and feeds back the actual operating status of the motor to the control system. In a closed-loop control system, the controller adjusts the input current and voltage of the motor in real-time based on the signals feedback from the encoder to ensure that the motor operates according to the predetermined trajectory and speed. This closed-loop control method can effectively improve the positioning accuracy and operational stability of the motor, reducing speed fluctuations caused by load changes or external interference. For some equipment with extremely high motion accuracy, such as semiconductor manufacturing equipment and precision CNC machine tools, BG motors with closed-loop feedback of encoders can significantly improve the processing accuracy and product quality of the equipment. Even if the equipment encounters sudden load changes during operation, the closed-loop control system can quickly make adjustments to maintain the stable operation of the motor, thereby improving the reliability and production efficiency of the equipment.

Practical application case: In the PCB board cutting equipment of an electronics factory, the original open-loop control motor caused a cutting error of more than ±0.03mm due to load fluctuations when cutting 0.1mm fine lines, and the scrap rate was as high as 12%. Due to the limited space on the machine's bench, it is not possible to install an external positioning sensor. BG customized a closed-loop motor with an integrated 1024-wire encoder to keep the installation dimensions the same by embedding the encoder assembly into the original motor housing. After the transformation, the positioning accuracy of the system has been improved to ±0.005mm, the cutting error is stable within ±0.01mm, and the scrap rate has been reduced to less than 1.5%, reducing the cost of raw material loss for the enterprise by about 800,000 yuan per year.

Silent bearing + dynamic balance motor design

Excessive operating noise is often a problem for many devices, especially in some noise-sensitive working environments. BG motors effectively reduce noise and vibration during motor operation by selecting high-quality silent bearings and carefully designed dynamic balance structures. The silent bearing is designed with special materials and structure, which reduces the friction and collision noise between the bearing rolling element and the raceway. At the same time, BG motors have carried out high-precision dynamic balancing of the rotor during the manufacturing process to ensure that the motor will not produce vibration and noise due to rotor imbalance when rotating at high speed. This combination of silent bearings and dynamic balance motor design makes the motor run more smoothly and the noise is greatly reduced. For applications with strict noise requirements, such as office equipment and medical equipment, equipment using BG motors can provide users with a quieter and more comfortable working environment, while also helping to extend the service life of the equipment and reduce component wear and failure caused by vibration and noise.

Practical application case: A hematology analyzer in a hospital made a noise of 68 decibels when the original motor was running, affecting the laboratory environment and interfering with precision testing equipment. The internal space of the device is compact and it is not possible to add a sound shield. BG customized a silent bearing + two-stage dynamic balancing motor for it, which reduced the operating noise to 42 decibels while maintaining the original installation size by using ceramic ball bearings and rotor double-sided dynamic balancing process. The retrofitted equipment meets the ICU ward silence standard, improves the stability of detection data by 20%, and extends the motor bearing life from 8,000 hours to 15,000 hours, reducing equipment maintenance downtime.

In the case of limited mechanical structure of equipment, by choosing customized solutions provided by BG motors, such as upgrading high-efficiency electromagnetic structure, increasing encoder closed-loop feedback, and selecting silent bearings + dynamic balance motor design, etc., the motor performance can be optimized without changing the mechanical structure, thereby improving the overall performance of the equipment and meeting the needs of various complex industrial applications.