Xi'an Simo as a DC Motor supplier. Our motor products are widely used in many industries, including high-tech fields such as electric power, coal mining, petroleum, metallurgy, railways, transportation, chemical industry, agriculture, water conservancy and aerospace. At the same time, we are also designated as a supplier of auxiliary motors by the Ministry of Railways and General Electric. We always adhere to the market-oriented and customer-oriented business philosophy. Our products not only cover sales and service networks across the country, but are also exported to more than 40 countries and regions in North America, Europe, Africa, the Middle East and Southeast Asia.
What is DC motor?
DC motor is based on the law of electromagnetic induction and the left-hand rule A magnetic field is generated when a direct current passes through the coil of a motor The coil is rotated by torque in the magnetic field Specifically, when the armature winding is energized, the armature will start to rotate under the action of ampere force, thus converting electric energy into mechanical energy DC motor is mainly composed of stator and rotor Stator includes base, main magnetic pole, commutator and brush device, and rotor (also called armature) includes armature core, armature winding, commutator and rotating shaft When the motor works, the brush and commutator supply current to the armature winding to make it rotate under force in the magnetic field.
What are advantages of dc motor?
Low Loss
The existence of these losses means that the motor does not convert all the electrical energy input into effective mechanical energy, but some of the energy is wasted as heat energy or other forms Therefore, it is very important to understand these losses for improving the efficiency and performance of motors.
High Efficiency
The high efficiency of the motor includes the loss through the improvement of design materials and technology, so as to improve the efficiency of the motor.
Compact Structure
The structural compactness of the motor is mainly reflected in its design and construction. By optimizing the layout and connection of various components, the whole motor is more compact.
Stable Operation
The stable operation of motor not only requires the electromagnetic torque equal to the load torque, but also requires that the system can be restored to the original state after being disturbed, that is, the mechanical characteristics of the system and the load characteristics have an intersection point and this intersection point has a specific dynamic stability condition.
Low Vibration
The realization of low vibration conditions of motor mainly depends on the comprehensive optimization of many aspects, including the design, manufacture, installation and maintenance of motor.
Low Noise
The reasons of low noise of motor mainly include optimizing design, improving manufacturing and assembly accuracy, improving use and strengthening maintenance, etc.
Long Service Life
The reason for the long life of the motor is mainly due to the rationality of its design and use, as well as subsequent maintenance. The life of the motor is affected by many factors, including electrical performance, mechanical performance, factors and improper use.
Types of dc motor
Z Series DC Motor
Z4 series of motor is newly developed medium sized DC motor since Z4 series small size DC motor, which adopts advanced design and polygonal lamination structure for stator framework, fully utilizing space effectively. The whole stator and rotor adopts solvent-free paint vacuum pressure immersion treatment (VPI), making winding with good moisture resistance ability and mechanical strength and the insulation and heat-conducting property is good. Stator magnet yoke, pole, armature core are all made by overlaying fine silicon steel plates. This series of motor mainly applied in all kinds of industrial departments, such as metallurgical industrial rolling mill, metal cutting machine, paper-making, dyeing and weaving, printing, cement, plastic extrusion machines, etc.
Z4 Series DC Motor
Z4 DC motor has more advantages than Z2 and Z3 series. It can not only supplied by direct current power, but also suitable to be supplied by static rectifying power. And the smaller rational inertia is, the better dynamic performance. Z4 motor can bear a higher rating of load, especially suitable for smooth speed control, high efficiency, automatic steady speed, sensitive control system. It has reached the international advanced level.This series of motor has fine speed adjusting characteristic which is smooth, convenient and its speed adjusting range is wide. (Rated speed adjusting upwardly is constant power and downwardly is constant torque). The potential wave is better, electromagnetic interference influence is smaller, the overload capacity is stronger and it can bear frequent impulse overload with a larger starting and braking torque. Z4 DC motor (Frame size 100-355mm) can be widely applied in metallurgical industry, such as rolling mill, metal cutting machine, paper-making, textile, printing, cement, plastic extruder and other industry. It is suitable for situations that require wide speed control scope, electric dragging where overload ability should not exceed 1.6 times.
Z2 Series DC Motor
Z2 series of DC motor is generally industrial small size DC motor, which requires constant power speed range no larger than 2:1, and overload capacity no larger than 1.5 times of electric traction of rated torque. The basic structure of motor adopts drop-proof uniaxial extension, self-fan cooled structure, applying in general normal working conditions. This series of motor applies in industries of metal cutting machine, paper-cutting, dyeing and weaving, printing, cement, etc. This series of motor has fine speed adjusting characteristic, reliable property and no need of direct AC power supply. It is with internal fan and self-ventilation.
Material of DC motor
Cooper
Copper is a very ductile metal and can be drawn into round wires with different diameters. Based on the diameter, the current carrying capacity of copper winding wire varies. For example, thinner wires are used in headphones, charging cables etc. Whereas, thicker copper wires are used in transformers, motors etc. Copper can be drawn into flat shapes to form rectangular winding wires. Rectangular winding wires are integral components in compact and high-performance applications like electric vehicle motors, EV power trains etc.
Cast Iron
Cast iron is a good choice for an engine block. It is easily sand cast, easy to machine, capable to resist piston wear quite well, and inexpensive as a material. Others have attempted to use things like Aluminum or even more exotic materials like Magnesium. But there are always additional expenses in those cases, and additional complexity. In the end, while an aluminum block is lighter, it just doesn’t stand up to wear as a cast iron block does.
Steel
Silicon steel is the most common lamination material for motor cores. It offers high electrical conductivity, low hysteresis loss, excellent corrosion resistance, and relatively low cost. Electrical steel laminations are perfect for larger machines where cost-effectiveness and energy efficiency are prime considerations.
Silicon steel sheet
Silicon steels are ferritic alloys of iron and silicon that have magnetic properties which make them useful in motors and transformers. The silicon additions improve magnetic softness and increase the electrical resistivity.
Application of dc motor
Metallurgical industrial rolling mill
Z series medium-sized DC motor shows its wide application potential in the application of coal mill These motors are not only suitable for static rectifier power supply, but also can provide superior performance in dynamic performance, load change rate and efficiency Especially in the application of coal mill in mining industry, the use of DC motor further improves the performance and efficiency of coal mill.
Metal cutting machine
The application of DC motor in the field of machine tools is mainly reflected in the production requirements of providing power and controlling high precision and high efficiency DC motor is widely used in industrial production, especially in the field of machine tools They are regarded as an important power source, which can provide stable speed and large torque, which is very important for high precision and high efficiency operation of machine tools.
Paper-making
Paper industry is one of the important application fields of DC motor As the core power source, the selection and configuration of DC motor in papermaking machinery have a significant impact on improving production efficiency and products For example, the power matching and performance of Z4-225-11 55KW vertically mounted V1 motor are very important for the operation of papermaking machinery.
Plastic extrusion machines
The application of DC motor in plastic extrusion machinery is very extensive, including but not limited to metallurgical industry, rolling mill, metal cutting machine tool, paper making, dyeing, weaving, printing, cement production and plastic extrusion machinery itself As an important equipment in plastic processing industry, plastic extrusion machinery can not improve its operation and performance without the support of high-efficiency motor DC motor plays a key role in plastic extrusion machine because of its good speed regulation performance and large starting torque As a kind of small DC motor series, Z4 series DC motor is not only suitable for DC power supply but also for static rectifier power supply, which makes it more flexible and adaptable in various industrial applications.
How to maintain dc motor?
1. Operation environment
The operation altitude shall not exceed 1,000m and the ambient air temperature varies with seasons, but the maximum temperature shall not exceed 40℃ and the minimum temperature shall not be lower than -15℃.The high relative humidity of the ambient air is 100%, and the high absolute humidity is 25g/m³.
2. Mechanical inspection
After receiving the motor, after unpacking immediately to check whether there is any damage during transportation, and carefully remove the dust on the motor and the anti rust coating at the shaft extension; if any damage is found, please inform the transporter immediately. Check whether the spare parts are completely assembled and whether the fasteners are loose or fall off. For the motor with shaft extension fixed device, the fixed device of shaft extension shall be removed first, and then the rotor shall be rotated by turning gear to check whether the rotation is flexible.
3. Electrical Inspection
The insulation resistance of motor shall be measured with 500V megger, and the value shall not be less than 0.5mΩ. The humidity heat type motor shall not be less than 1mΩ. If it is lower than the above requirements, it should be dried.
4. Motor operation
The motor can be started directly with the power supply. The step-down starting if the power supply capacity is insufficient.The power supply of motor shall be equipped with multi-channel protection devices such as overheat protection, short-circuit protection, open phase protection and zero sequence protection, so as to prevent single protection failure.
5. Storage and lifting of motor
The motor should be always stored in the dry, vibration-free and dust-free indoor environment, and should not be stored in the wet warehouse with acid and alkali, rats or other easy corrosive gases. For the motor without being installed temporarily, the machining fitting surface (such as shaft extension and flange) of exposed parts of motor should be coated with anti-rust oil for protection in case of corrosion.
Components of dc motor
Rolling bearig
Roller bearings — also known as rolling-element bearings — are similar to ball bearings in that they are designed to carry a load while minimizing friction.
However, roller bearings transmit loads using cylinder rolling elements, rather than balls, to maintain the separation between moving parts of the bearing.
These versatile bearings can contain single or multiple rows of rolling elements; multiple rows can significantly improve radial load capacity. Also, the use of different roller shapes can further reduce friction and support both radial and axial loads.
Sliding bearing
Sliding bearings are bearings where only sliding friction is generated. The shaft is generally supported by the sliding surface, with oil and air in between to facilitate sliding movement. Sliding bearings are lightweight and have a long operating life while introducing minimal vibrations or noise.Sliding bearings made of resin material for slippery surfaces or shafts, that are suited to a wide range of fields and machine components with their lighter weight, lower cost and versatility compared to metal. They are lightweight and generate less vibration and noise, and have a lower slip friction coefficient. They also exhibit excellent plastic workability and electrical insulation when heated, and are water and chemical-resistant.
Coil
Electromagnetic induction phenomenon not only plays a key role in electric motors, but also plays an important role in electrical equipment such as transformers and generators For example, in a transformer, the voltage is changed by changing the current in the coil to change the magnitude of the induced electromotive force.
Insulation Material
Insulation materials used in motors include many types, which can be mainly divided into the following categories: Film and composite materials for electrical purposes, such as polyester film, polynaphthyl ester film, polyimide film, etc., used for winding insulation and winding gasket insulation of motor coils Insulating mica and its products
Silicon Steel Sheet
The role of silicon steel sheet in motor is to improve the resistivity and maximum permeability of iron, coercivity, core loss (iron loss) and magnetic aging Silicon steel sheet used in motor is also called electrical steel sheet, which is an important electrical material and is mainly used to manufacture the core of motor, generator and transformer This material optimizes the performance of the motor by increasing the resistivity and maximum permeability of iron as well as coercive core loss (iron loss) and magnetic aging Specifically: Increased resistivity and permeability
Temperature Detector
Function of a motor temperature sensor Motor temperature sensor is a kind of equipment used to measure the temperature of motor It can be installed on the motor to monitor the change of motor temperature
Process of dc motor
Stator
The fixed part of a motor called the stator on which a pair of stationary main poles for DC excitation are installed Stator windings can be divided into two types: centralized and distributed according to the winding shape and embedded wiring These windings generate magnetic fields when they are energized to provide the necessary electromagnetism for the operation of the motor. Stator punching sheet adopts high-speed multi-slot punching stator core adopts external pressing process winding is manufactured by special equipment manual off-line vacuum impregnation electrical insulation test.
Rotor
Rotor: The rotating part is called rotor. It is equipped with an armature winding that generates induced electromotive force to act as a rotating magnetic field after being electrified The rotor rotates because the magnetic field generated by the stator interacts with the current in the rotor to produce electromagnetic torque to drive the rotor to rotate. The rotor punching sheet adopts high-speed multi-groove punching rotor core adopts centrifugal casting aluminum process.
Frame
The main function of the motor base is to fix the stator core and the front and rear end covers to support the rotor and play a role in protection and heat dissipation.
Final Assembly
Firstly, the iron core is fixed into the stator slot and an insulating material is injected to fix the iron core inside the stator slot Then the electromagnetic coil is wound on the stator slot and connected with the iron core Then install the rotor and rotor bearings, and finally install the end cover bracket and other components to complete the final assembly of the motor.
FAQ
Q: What is environment requirements of DC motor?
1. The operation altitude should not exceed than 1000m.
2. Environment temperature changes with seasons, however, the highest temperature should not exceed than 40℃ and the lowest temperature should not less than 0℃.
3. This series and its derived DC motors can be installed in some poor areas with tough environment, however, correct cooling mode and protection grade should be selected to guarantee the cooling and cleaning of motor.
4. The working environment and cooling air applied to this series of motors and its derived DC motors should be free of acid, basic and other gas which may cause damage towards motor insulation and commutator working surface roughness electric brush.
5. Please note in advance if this series of motors and its derived DC motors will be applied on ship, tropic zones or other environment with salt mist and humid weather conditions, or it would affect the motor operational quality and service life.
Q: What is lifting, storage, installation conditions of DC motor？
2. Motors should be store indoors with dry, dust-free and corrosive gas free environment if the motor shall not be put into service recently. The temperature should not less than 5℃ and the temperature should not exceed 75%.
3. Check bearing grease after box-opening if the motor has been stored beyond two years, replace if necessary.
4. Motor installation areas should have fluent ventilation without hinder, what's more, the emitted hot air should be avoided to enter into the motor directly.
5. The motor must be installed on steel structure pedestal with enough steel rigidity, or cement pedestal. During concrete pouring, (around 2mm) gasket should be added between motor supports and cement pedestal so as to correct the adjustment.
6. During connection between motor and working machine, two axles should be concentric, thus, careful calibration and check should be conducted.
7.Motor bearing extension shall not bear over impact during installation of coupling or belt pulley. It is allowable to use shrinkage fit, but compulsory cooling is required, which makes the bearing temperature not higher than 95℃. Professional tools should be used for dismantling with damage the center hole of bearing head.
Q: How to operate DC motor?
2. Mechanical check. Check if all fasteners are well fastened. Rotate the armature by hands to check if there is block, crash or friction.
3. Open the commutator cover or blinds to check if there is pollution, steam, or rust on the surface of commutator and check if the brush is in completed condition.
4. Check the insulation resistance. The winding-to-casing insulation resistance should be less than 1 Megohm under indoors temperature.
5. If there are no any problems in accordance with motor checking, please arrange adjustment and installation as per the above requirements and check if each accessory wiring is correct and wiring of grounding is good, safe and reliable.
6. Start-up, operation and stop
● As for motors with non-adjustable power supply, starter should be used during start-up period. Adjust the starter resistance value to maximum firstly and cut off gradually during start-up. As for external ventilation motor, start the ventilator and separate excitation motor firstly and then input the rated excitation voltage, gradually rise up the armature voltage to rated voltage. The start-up current should be controlled less than 2 times of rated current, the instant starting impulse current should no larger than 3 times of rated current.
● Once started, the motor operates as per working method regulated by nameplate, and it should not exceed than the overload capacity and operation time so as not to damage the motor. The flux weakening rotation speed should adopt the highest rotation speed regulated by motor nameplate to avoid loss of excitation, which may cause damage to motor or transmission system.
● The stopping procedures are opposite with starting procedures. Decrease gradually the armature voltage and lower the motor rotation speed to minimum, cut off the armature power supply, which stops the motor. As for separate excitation motor, when stops at armature, adjust the excitation voltage, gradually decrease to zero and cut off the excitation voltage. The external ventilation motor cooling fan should continuously run 10-15mins and then cut off the power supply of ventilator.
Q: How to maintain DC motor?
2. The maintenance of commutator. The commutator should be in good condition before leaving factory. The amaranth hard film produced on motor surface can decrease the wearing of commutator during motor running period; the mentioned film shall not be removed.
3. The brush should be in good contact with the surface of commutator and the normal brush pressure should be 0.015～0.025 MPa. The match between brush and brush box should not be too tight and proper clearance should be kept (0.04～0.31 mm, the small value is applicable for small brush and the big value is applicable for big brush).
4. As for motor supported with fan external ventilator, if too much dust accumulated on dust filter, the ventilation quantity of motor will be reduced and the temperature of motor will rise, thus, the ambient environment should be highly focused and periodically cleaning should be done towards dust filter. Generally, the cleaning should be conducted once a week or once a month. As for the cleaning of dust filter, compressed air can be used if there is dust without oil contamination, or sucking out with dust collector. Raising and drying should be done in accordance with dust with oil contamination.
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