DRIVE-SYSTEM motor Germany DRIVE-SYSTEM model DRIVE-SYSTEM price

DRIVE-SYSTEM motor is a rotating motor containing a brush assembly that converts DC electrical energy into mechanical energy (DC motor) or converts mechanical energy into DC electrical energy (DC generator). Distinct from brushless DC motors, the brush assembly is used to introduce or extract DC voltage and DC current. Brushed DC motors are the foundation of all motors; they feature fast starting, timely braking, smooth speed regulation over a wide range, and relatively simple control circuits.

DRIVE-SYSTEM motor classification

Motors are divided into three-phase and single-phase types based on the number of phases. For the same volume, the output of a three-phase reluctance synchronous motor is 1/3 to 2/3 higher than that of a single-phase reluctance synchronous motor. Single-phase reluctance synchronous motors are further classified by starting method into capacitor-start, capacitor-run, and capacitor-start-and-run types. Capacitor-start motors have high starting torque. Capacitor-run motors offer good running performance, high efficiency, high power factor, and low noise, but have lower starting torque. Capacitor-start-and-run motors combine the advantages of both, offering higher starting torque and better running performance. A reluctance synchronous motor is a type of miniature synchronous motor. Its rotor has a salient-pole structure; externally, it is a cylinder or disc, constructed from magnetic and non-magnetic materials. The magnetic reluctance along the direct axis is lower than along the quadrature axis, creating a salient-pole magnetic effect. When the stator winding is energized, a rotating magnetic field is generated in the air gap. This field produces magnetic pull, dragging the rotor to rotate synchronously. A reluctance synchronous motor is a synchronous motor with an unexcited rotor featuring regularly shaped salient poles, equipped with a squirrel-cage winding for starting or without one; it is also known as a switched reluctance motor. A reluctance motor is equivalent to a salient-pole synchronous motor without excitation windings, generating electromagnetic torque by utilizing differences in magnetic reluctance in the rotor magnetic circuit.

DRIVE-SYSTEM motor mechanical characteristics

Motors are widely used in electric vehicles because they offer two main advantages over traditional brushed DC motors. (1) Long service life, maintenance-free, and high reliability. In brushed DC motors, due to high rotational speeds, brushes and commutators wear out quickly, typically requiring brush replacement after about 1000 hours of operation. Additionally, the technical difficulty of gearbox technology, particularly lubrication of transmission gears, is a major challenge in brushed solutions. Therefore, brushed motors suffer from issues such as high noise, low efficiency, and prone to failure. Thus, the advantages of brushless DC motors are evident. (2) High efficiency and energy saving. Generally, because brushless DC motors lack friction losses from mechanical commutation and gearbox consumption, as well as losses in the speed control circuit, efficiency can typically exceed 85%. However, considering the best cost-performance ratio in actual design and to reduce material consumption, they are generally designed for 76%. In contrast, the efficiency of brushed DC motors, due to consumption in the gearbox and overrunning clutch, is typically around 70%.

DRIVE-SYSTEM motor structure

The motor armature core is the main part of the main magnetic circuit and is used to house the armature winding. Generally, the armature core is made by stacking laminations punched from silicon steel sheets 0.5mm thick to reduce eddy current and hysteresis losses generated in the armature core during motor operation. The stacked core is fixed to the shaft or rotor bracket. Armature slots are cut into the outer circumference of the core, and the armature winding is embedded in these slots. The function of the armature winding is to generate electromagnetic torque and induced electromotive force (EMF); it is the key component for energy conversion in DC motors, hence the name 'armature'. It consists of many coils (hereinafter referred to as elements) connected according to a specific pattern. The coils are wound using high-strength enamel-coated wire or glass-fiber-insulated flat copper wire. The coil sides of different coils are embedded in two layers (upper and lower) in the armature slots. Proper insulation must be maintained between the coils and the core, as well as between the upper and lower layers of coil sides. To prevent centrifugal force from throwing the coil sides out of the slots, the slot openings are secured with slot wedges. The end connections of the coils extending outside the slots are bound with thermosetting non-woven glass tape. In DC motors, the commutator, paired with brushes, converts the external DC power supply into alternating current in the armature coils, keeping the direction of electromagnetic torque constant. In DC generators, the commutator, paired with brushes, converts the alternating EMF induced in the armature coils into DC EMF extracted at the positive and negative brushes. The commutator is a cylinder composed of many commutator segments, insulated from each other by mica sheets. The shaft supports the rotation of the rotor and requires sufficient mechanical strength and rigidity; it is generally machined from round steel.

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