A Comprehensive Guide to Custom Motor Manufacturing Process

CJC specializes in providing tailored solutions for various scenarios and applications (home appliances, medical care, smart homes, robotics, etc.). We not only focus on product performance and functionality but also prioritize meeting your personalized needs. Leveraging years of industry experience and professional expertise, we assist you in creating innovative products that meet market demands and ensure reliability to meet high market standards.

Advantages

- In-house Research and Development: With a robust R&D team, we independently develop motor control software and hardware, completely mastering intellectual property rights. We deeply understand your requirements and tailor solutions accordingly.

- Global Presence: With production and service networks spread across various locations (Guangdong, Hunan, Cambodia, North America), we provide rapid and flexible services, ensuring quick response times.

- Market-oriented: Centered around customer needs, we collaborate closely and continuously introduce new products. Through in-house software and hardware development, we ensure synchronization with the market.

- Efficient Response: 24-hour response across business, technical, and project aspects, providing customized solutions.

- Cost Advantage: Self-production of key components (core mold design and product processing), offering thousands of standard components, selecting materials and components with high cost-effectiveness, effectively reducing production costs of motor products. Improvements in core design and the use of domestically produced MCUs lower costs while ensuring performance.

Requirements Analysis

Client perspective:

• Are you searching for a suitable motor for a specific project?
• Are you dissatisfied with existing motor products?
• Do you require a custom motor to meet unique requirements?
• Do you need a no-obligation quote?
• Do you need to provide samples for a specific technical plan?

Business perspective:

• Our project and technical teams leverage CJC MOTOR's extensive motor database to recommend the most suitable and cost-effective motor type and model based on your specific needs.

Required information:

1. Motor application scenario
2. Motor performance parameters (speed, torque, power, efficiency, etc.)
3. Motor size, weight, and cost requirements
4. Other special requirements (explosion-proof, waterproof, dustproof, etc.)
5. Customer budget
6. Approximate demand quantity for the required motor
7. Customer product release schedule
8. Information on competitors, relevant industry standards and regulations, and functional specifications

If you cannot find a motor that meets your requirements, CJC MOTOR can collaborate with you to develop a custom solution tailored to your specific needs.

Conceptual Design

Client perspective:

• Do you want to receive multiple design proposals for comparison and selection?
• Do you need the design proposals to meet your budget requirements?
• Do you require a comprehensive testing plan?

CJC MOTOR Solution:

• We provide multiple design proposals tailored to your specific needs, accompanied by detailed evaluations.
• We offer cost estimates to assist you in selecting the most optimal design.
• We provide a comprehensive testing plan that includes laboratory testing and certification.

Technical Design

Comprehensively consider motor performance, cost, reliability, and other factors.

Utilize computer-aided design (CAD) software and other tools to enhance design efficiency and accuracy.

Client perspective:

• Ensure smooth motor startup and achieve target speed.
• Guarantee necessary motor safety and reliability.
• Fulfill customer's personalized requirements, such as speed control, torque control, and position control.

Business perspective:

Adhere to the principles of safety, reliability, efficiency, and cost-effectiveness.

Motor startup:

• Control part (simulation)
• Bottom layer implementation (driver)
• Initial magnetization: Provides the motor with an initial magnetic field to overcome static friction and initiate rotation.
• Magnetic field establishment: Adopts a suitable magnetization method based on the motor type and control method.
• Speed ramping: Gradually increases motor speed by controlling voltage or current to achieve a stable operating state.

Driver design:

• VF control: Similar to starting a car, gradually applies throttle to initiate motor movement.
• IF control: Analogous to car gear shifting, adjusts motor speed and force based on requirements.
• FOC control: Resembles car autopilot, enabling precise motor control.

Motor protection:

• Overcurrent protection: Disconnects power or reduces voltage when motor current exceeds the set value to prevent motor overheating and damage.
• Overvoltage protection: Implements measures to limit voltage when it exceeds the rated value to prevent motor insulation damage.
• Overtemperature protection: Takes measures to reduce motor temperature when it exceeds the set value to prevent motor overheating and damage.
• Stall protection: Disconnects power or reduces voltage when motor stalls to prevent motor damage.
• Phase loss protection: Disconnects power or reduces voltage when motor loses phase to prevent motor damage.

Our custom motors can be equipped with a variety of features to meet your specific needs, including:

• Speed control: Control the motor's speed by adjusting voltage, current, or frequency.
• Torque control: Control the motor's torque by adjusting voltage, current, or magnetic field.
• Position control: Achieve precise positioning of the motor by controlling its speed and torque.
• Communication capabilities: Add a communication interface between the motor and the上位机 to enable motor parameter setting, status monitoring, and fault diagnosis.

Rapid Prototyping

We believe that rapid prototyping is essential for validating design concepts and identifying potential issues early in the development process. Our prototyping capabilities include:

• CNC machining
• 3D printing
• Rapid tooling

Product Development Cycle

Aftermarket Support

We stand behind our products with a comprehensive aftermarket support program. If your motor does not meet your expectations, we will work with you to resolve the issue.

Coffee Grinder BLDC Motor: A Custom Solution for Superior Performance

Introduction

This case study presents the development of a custom brushless DC motor for a small coffee grinder. The goal was to provide a high-performance, low-noise, and reliable motor that would enhance the user experience and enable new features.

Customer Requirements

The customer specified the following requirements for the motor:

• Low noise and vibration for a comfortable user experience
• Powerful torque and speed control to meet different coffee bean grinding needs
• Comprehensive safety protection features to ensure safe operation

Design and Development

1. Motor Selection

To meet the customer's requirements, a brushless DC motor was selected. Brushless DC motors offer several advantages over traditional brushed motors, including:

• Higher efficiency and lower power consumption
• Reduced noise and vibration
• Longer lifespan
• Improved reliability

2. BL7160 Performance Parameters

3. Safety Features

The motor incorporates several safety features to ensure safe operation, including:

• Overvoltage protection
• Undervoltage protection
• Overcurrent protection
• Stall protection

The product has also passed multiple safety certifications, including 3C and UL, and meets relevant electromagnetic compatibility standards.

4. Noise and Vibration Reduction

To achieve the customer's low noise and vibration requirements, the following measures were taken:

• Optimized motor design and structure
• Use of high-quality bearings and vibration-damping materials
• Low-speed operation during grinding

5. Size and Weight Optimization

To meet the customer's size and weight requirements, the following measures were taken:

• Use of lightweight materials
• Compact design

The motor has an outer diameter of 71mm and a length of 60mm, making it easy to integrate into the coffee grinder.

6. Application Adaptability

The motor is designed for easy installation in various food搅拌类电器, such as coffee machines, grinders, and blenders. It can also be customized to meet the specific requirements of different applications.

Performance Testing and Validation

After the design was finalized, extensive performance testing and validation were conducted to ensure that the motor met all customer requirements and performance指标. The tests included:

• Speed
• Torque
• Efficiency
• Noise
• Vibration
• Safety features

Production and Manufacturing

A production and manufacturing plan was developed, including the selection of appropriate production processes and material suppliers. Strict quality control measures were implemented to ensure the quality and performance of the product.