JGB37-3530A DC Motor: Optimization Journey to Enhance Smart Wheelchair Performance
In the wave of smart device innovation, an efficient and reliable motor is a crucial driving force behind the intelligence of these devices. Recently, a company specializing in smart device development introduced the 37mm diameter JGB37-3530A DC motor into its new smart electric wheelchair. However, during actual application, the R&D team encountered several challenges that significantly impacted the product's performance and user experience. After in-depth analysis and a series of optimization measures, these issues were effectively resolved, significantly enhancing the overall performance of the product.
I. Project Background
The company has always been dedicated to developing smart electric wheelchairs to meet the market's demand for efficient, convenient, and low-noise devices. During the early product testing phase, the R&D team found that traditional motors generated considerable noise during operation and exhibited unstable torque output under high load, which severely impacted the device's overall performance and user experience. To overcome these challenges, the R&D team began searching for a high-performance miniature motor and ultimately selected the JGB37-3530A DC motor.
II. Problem Description
(1) Noise Issue
During operation, the motor produced relatively high noise levels, especially when running at low speeds, which was particularly noticeable. This not only affected the user experience but also had the potential to cause noise pollution in residential environments.
(2) Unstable Torque Output
Under high load, the motor's torque output fluctuated significantly, resulting in an uneven driving process for the wheelchair. This not only affected the device's operational efficiency but also raised concerns about potential long-term mechanical issues.
(3) Heat Dissipation Problem
After prolonged operation, the motor's temperature increased, affecting the stability and lifespan of the device. This was particularly evident during high-frequency use and could lead to overheating and automatic shutdown of the device.
III. Problem Analysis
(1) Noise Issue
The noise primarily originated from the meshing of gears inside the motor and vibrations of the motor housing. At low speeds, the meshing frequency was lower, but each meshing event released a significant amount of energy, resulting in more noticeable noise.
(2) Unstable Torque Output
The instability in torque output was likely due to an imprecise control algorithm that caused significant current fluctuations when the load changed, thereby affecting torque delivery. Additionally, there might have been design flaws in the motor's gear transmission system that led to uneven torque transfer.
(3) Heat Dissipation Problem
The poor heat dissipation was probably due to inadequate cooling design in the motor, preventing heat from being effectively dissipated. As a result, the internal temperature of the motor increased during extended operation, impacting its performance and longevity.
IV. Optimization Solutions
(1) Noise Optimization
- Gear Design Improvement: Replaced spur gears with high-precision helical gears to optimize the gear meshing angle and reduce noise during meshing.
- Sound-Insulating Materials: Added sound-insulating materials, such as rubber pads or sound-absorbing sponges, inside the motor housing to absorb noise generated during operation.
- Motor Installation Optimization: Ensured that the motor was securely fastened during installation to reduce housing vibrations, thereby lowering noise levels.
(2) Enhancing Torque Stability
- Control Algorithm Optimization: Implemented a closed-loop control algorithm to monitor the motor's current and torque output in real-time and automatically adjust operating parameters according to load changes to ensure stable torque delivery.
- Torque Compensation Module: Integrated a torque compensation module into the motor control system to dynamically compensate for torque output through software algorithms, reducing torque fluctuations during startup and shutdown.
(3) Heat Dissipation Optimization
- Heat Sink Addition: Installed heat sinks on the motor housing to increase the surface area for heat dissipation and improve cooling efficiency.
- Internal Structure Optimization: Redesigned the air flow channels inside the motor to add ventilation holes, ensuring effective heat dissipation during operation.
- Thermal Conductive Materials: Applied thermal conductive silicone to key components inside the motor to quickly transfer heat to the housing, further enhancing cooling performance.
V. Implementation Results
(1) Noise Reduction
After optimization, the motor's operating noise was reduced from 60 decibels to 50 decibels, significantly improving the user experience and reducing noise pollution in residential settings.
(2) Enhanced Torque Stability
Torque output stability was improved by 30%, resulting in a smoother driving process for the wheelchair and a noticeable increase in the device's operational efficiency. The long-term stability of the motor was also enhanced.
(3) Improved Heat Dissipation
The motor's operating temperature was reduced by 20%, eliminating instances of overheating and automatic shutdown, and significantly enhancing the device's continuous operation capability.
VI. Conclusion
By addressing the noise, torque stability, and heat dissipation issues of the JGB37-3530A DC motor, the R&D team successfully resolved the practical problems encountered in application, significantly enhancing the performance and user experience of the smart electric wheelchair. These improvements not only solved the immediate issues but also provided valuable insights for similar application scenarios. Looking ahead, with continuous technological advancements, the JGB37-3530A motor is expected to play a significant role in more smart devices, bringing greater convenience and innovation to people's lives.