A continuous potting device applied to a brushless direct current motor end cover

Abstract

This invention discloses a continuous potting device for end caps of brushless DC motors. A conveyor belt is mounted on the horizontal section of the main conveyor frame, and an electrically controlled rotating frame is mounted on the arc-shaped section. An adjustable-position top dispensing module is mounted on the top of the main conveyor frame via a height-adjustable top bracket. A top mounting bracket with a top-mounted suction plate is mounted via a first rotating bracket, and a bottom mounting bracket with a bottom heat treatment module is mounted via a second rotating bracket. The end cap is fed in by the conveyor belt and then transferred to the dispensing station via the electrically controlled rotating frame. The top dispensing module automatically dispenses adhesive, followed by curing by the bottom heat treatment module. The entire process requires no manual intervention. This invention achieves fully automated continuous operation of the end cap potting process, significantly improving potting efficiency and product consistency, while reducing labor costs and product loss.

Description

Technical Field

[0001] This invention relates to the field of motor assembly technology, and in particular to a continuous potting device for end caps of brushless DC motors. Background Technology

[0002] Brushless DC motors are widely used in industrial automation, new energy vehicles, and home appliances due to their high efficiency, long lifespan, and low noise. The end cap of a brushless DC motor is a crucial component, integrating electrical components such as Hall sensors, control circuit boards, and lead harnesses. To protect these components from moisture, dust, and vibration during long-term motor operation, the end cap typically requires potting. The potting material is generally epoxy resin or polyurethane resin, which is filled into the end cap cavity through pouring or injection. After curing, it forms a dense insulating protective layer, providing comprehensive functions including waterproofing, dustproofing, electrical insulation, heat dissipation, vibration damping, and wiring fixation.

[0003] Currently, the potting method for traditional brushless DC motor end caps mostly relies on semi-automatic or manual operations. The process is roughly as follows: operators place the end caps to be potted one by one on the potting station, the potting machine injects a measured amount of potting compound into the end cap's inner cavity, and then the operator removes the potted end caps from the station and transfers them to a curing tray. After all end caps in a batch are potted, they are sent to an oven or placed at room temperature to cure. Throughout this process, the loading, unloading, and transfer of end caps are entirely manual. Each process is independent and cannot be continuously connected. The potting station experiences significant idle time while waiting for manual operation, resulting in low overall production efficiency and difficulty in meeting the demands of mass production. Furthermore, inconsistencies in manual operation lead to fluctuations in the amount, speed, and location of the potting compound injected. The uniformity of potting within the same batch is difficult to guarantee, and some end caps may have localized missing compound or residual air bubbles, affecting potting quality and the long-term reliability of the motor. Meanwhile, the end caps are prone to collisions or tipping during manual handling, causing the injected potting compound to flow out or overflow before it has cured, further exacerbating the quality instability problem.

[0004] Therefore, how to achieve automation, continuity, and uniformity in the end cap potting of brushless DC motors is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0005] The technical problem to be solved by the present invention is that the existing brushless DC motor end cap potting method relies on manual loading, unloading and transfer, which makes it impossible to connect the various processes continuously, resulting in low potting efficiency, poor potting uniformity, and easy for potting glue to flow off course or overflow during manual handling, affecting product quality.

[0006] The technical solution adopted by the present invention to solve its technical problem is: a continuous potting device for end caps of brushless DC motors, including a main conveying frame, a conveyor belt installed on the horizontal section of the main conveying frame, an electrically controlled rotating frame installed on the arc section of the main conveying frame, a height-adjustable top bracket installed above the main conveying frame via a side bracket, a top mounting bracket installed above the main conveying frame via a first rotating bracket, a bottom mounting bracket installed below the main conveying frame via a second rotating bracket, a position-adjustable top potting module provided at the lower end of the crossbeam of the height-adjustable top bracket, a top suction plate installed at the lower end of the top mounting bracket via a top lifting support rod, and a bottom heat treatment module installed at the upper end of the bottom mounting bracket via a bottom lifting support rod.

[0007] Furthermore, the height-adjustable top support includes a longitudinal guide rail mounted on the side wall of the lateral support, a lifting frame slidably mounted on the longitudinal guide rail, and a side-mounted lifting strut. The side-mounted lifting strut controls the lifting frame to rise and fall along the longitudinal guide rail through telescopic control.

[0008] Furthermore, both the first rotating bracket and the second rotating bracket consist of a longitudinally placed guide cylinder fixedly installed on the side wall of the main conveying frame, a longitudinal synchronous shaft inserted inside the longitudinally placed guide cylinder, a rotating adjustment frame axially fixed to one end of the longitudinal synchronous shaft, and an electrically controlled worm gear assembly installed at the other end of the longitudinal synchronous shaft.

[0009] Furthermore, an arc-shaped guide rail is installed on the lower surface of the arc-shaped section of the main conveying frame. The electrically controlled rotating frame includes an annular adjustment frame that is slidably installed inside the arc-shaped guide rail and an adjustment motor installed on the arc-shaped guide rail. The adjustment motor is driven by an adjustment gear on the adjustment shaft that passes through the arc-shaped guide rail and meshes with the annular tooth groove on the annular adjustment frame.

[0010] Furthermore, a translation guide rail is fixedly mounted on the crossbeam of the lifting frame. The position-adjustable top dispensing module includes an adjustment platform that slides on the translation guide rail, a translation support rod installed on the adjustment platform, a top adjustment support rod fixed on the upper end of the adjustment platform, a dispensing cover installed at the bottom of the extended end of the top adjustment support rod, a dispensing component movably installed at the lower end of the dispensing cover, a detachable protective sleeve installed at the lower end of the dispensing cover, a top adjustment motor installed at the upper end of the dispensing cover, and an external dispensing hose.

[0011] Furthermore, an annular glue-guiding groove is provided on the lower surface of the glue-dispensing cover, which is connected to the external glue-dispensing tube.

[0012] Furthermore, the dispensing assembly includes an annular sealed cover that slides inside the annular dispensing groove and a dispensing nozzle that is fixed to the lower end of the annular sealed cover as an integral structure. An annular toothed groove is provided on the outer arc surface of the annular sealed cover. The top-mounted adjusting motor drives the annular sealed cover to rotate and adjust inside the annular dispensing groove by meshing with the annular toothed groove through the top-mounted adjusting gear.

[0013] Furthermore, the top-mounted suction cup includes a suction cup axially fixed to the extended end of the top lifting support rod, and an electrically controlled air pump connected to the inside of the suction cup via a flexible guide tube.

[0014] Furthermore, the bottom heat treatment module includes an adjustment base installed at the extended end of the bottom lifting support rod, a bottom sealing cylinder installed on the adjustment base, an electric control fan installed inside the bottom sealing cylinder, a built-in heating cylinder coaxially connected to the rotating end of the electric control fan, and an impact ball hinged to the side wall of the built-in heating cylinder.

[0015] Furthermore, an embedded electric heating element is installed on the inner side of the annular guide groove corresponding to the position of the annular toothed groove.

[0016] The beneficial effects of this invention are: (1) The present invention realizes the automatic feeding of end caps through the conveyor belt of the horizontal section of the main conveyor frame, and realizes the automatic transfer of end caps between workstations through the electric control rotating frame of the arc section. With the automatic picking and placing of end caps by the top adsorption plate, the end cap potting process is fully automated and continuous, from feeding, dispensing, curing to unloading, without manual intervention. The potting efficiency is more than 5 times higher than that of the traditional method. (2) The present invention achieves multi-degree-of-freedom precise positioning of the potting module by using a height-adjustable top bracket in conjunction with a translation guide rail and an adjustment platform. The top-mounted adjustment motor drives the dispensing component to rotate in the annular dispensing groove to achieve uniform dispensing of the potting compound. The embedded electric heating element is used to preheat and control the potting compound, ensuring the consistency of the amount of potting compound injected and the uniformity of the potting thickness, effectively avoiding the common problems of insufficient glue and air bubbles in traditional manual potting. (3) The present invention automatically rises to seal and heat the bottom of the end cap after the bottom heat treatment module is completed. The built-in heating cylinder rotates and drives the impact ball to generate vibration so that the potting adhesive is spread evenly. Combined with the electric control fan to force hot air circulation, it achieves rapid and uniform curing. The curing time is shortened to one-third of the curing time of traditional oven curing, and the curing quality is consistent. Attached Figure Description

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0018] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0019] Figure 2 This is a schematic diagram of the top mounting bracket in this invention.

[0020] Figure 3 This is a schematic diagram of the bottom heat treatment module in this invention.

[0021] Figure 4 This is a schematic diagram of the internal structure of the bottom heat treatment module in this invention.

[0022] Figure 5 This is a schematic diagram of the height-adjustable top support structure in this invention.

[0023] Figure 6 This is a schematic diagram of the internal structure of the glue-filling cover in this invention.

[0024] Explanation of reference numerals in the attached drawings: 100. Main conveyor frame; 110. Conveyor belt; 120. Electrically controlled rotating frame; 121. Arc-shaped guide rail; 122. Annular adjusting frame; 123. Adjusting motor; 124. Adjusting gear; 125. Annular toothed groove; 200. Side support; 300. Height-adjustable top support; 310. Longitudinal guide rail; 320. Lifting frame; 321. Translational guide rail; 330. Side-mounted lifting strut; 400. First rotating support; 410. Longitudinal guide cylinder; 420. Longitudinal synchronous shaft; 430. Rotation adjusting frame; 440. Electrically controlled worm gear assembly; 500. Top mounting bracket; 510. Top lifting strut; 530. Top suction cup; 531. Suction cup; 532. Flexible guide tube; 533. Electrical... 600. Controlled air pump; 700. Second rotating bracket; 710. Bottom mounting bracket; 800. Bottom lifting support rod; 810. Position adjustable top dispensing module; 820. Adjustment platform; 830. Translation support rod; 840. Top adjusting support rod; 841. Dispensing cover; 842. Annular guide groove; 843. Embedded electric heating element; 850. Dispensing assembly; 851. Annular sealed cover; 852. Dispensing nozzle; 853. Annular toothed groove; 860. Removable protective sleeve; 870. Top adjusting motor; 871. Top adjusting gear; 880. External dispensing hose; 900. Bottom heat treatment module; 910. Adjustable base; 920. Bottom sealing cylinder; 930. Electric fan; 940. Built-in heating cylinder; 950. Impact ball. Detailed Implementation

[0025] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0026] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0027] like Figure 1 , Figure 2 , Figure 3 , Figure 4, Figure 5 and Figure 6 As shown, a continuous potting device for end caps of brushless DC motors includes a main conveyor frame 100, a conveyor belt 110, and an electrically controlled rotating frame 120. The main conveyor frame 100 has an overall L-shaped structure, consisting of a horizontal section and an arc-shaped section connected at an angle to the horizontal section. The conveyor belt 110 is installed on the horizontal section of the main conveyor frame 100 to convey the motor assembly to be potted horizontally to the position of the electrically controlled rotating frame 120. An arc-shaped guide rail 121 is installed on the lower surface of the arc-shaped section of the main conveyor frame 100, and the electrically controlled rotating frame 120 is installed on the arc-shaped guide rail 121 to smoothly transfer the end cap delivered by the conveyor belt 110 to the potting station.

[0028] The conveyor belt 110 adopts an anti-slip synchronous belt structure and is driven by a servo motor through a reducer. The conveying speed is steplessly adjustable in the range of 0.1 to 0.5 m / s by a frequency converter. The positioning distance of the end cover on the belt is detected by a photoelectric sensor and then precisely controlled by a PLC to ensure that each motor assembly is synchronously connected with the electrically controlled rotating frame 120 when it reaches the arc section transfer position.

[0029] The electrically controlled rotating frame 120 includes an annular adjusting frame 122 slidably mounted inside the arc-shaped guide rail 121 and an adjusting motor 123 mounted on the outside of the arc-shaped guide rail 121. The inner arc surface of the annular adjusting frame 122 is equipped with rollers that roll along the guide groove of the arc-shaped guide rail 121. The outer arc surface of the annular adjusting frame 122 is machined with annular toothed grooves 125. The adjusting motor 123 is a stepper motor, and its output shaft drives an adjusting gear 124 through a reducer. The adjusting gear 124 passes through an opening in the side wall of the arc-shaped guide rail 121 and meshes with the annular toothed grooves 125. When the adjusting motor 123 receives a pulse command from the PLC, the adjusting gear 124 drives the annular adjusting frame 122 to slide back and forth along the arc-shaped guide rail 121, achieving precise transfer of the motor assembly from the end of the transverse section conveyor belt 110 to the dispensing station. For each pulse received by the adjusting motor 123, the annular adjusting frame 122 moves 0.05 mm, achieving a positioning accuracy of ±0.1 mm.

[0030] A lateral support 200 is fixedly installed above the main conveying frame 100. A longitudinal guide rail 310 and a side-mounted lifting strut 330 are installed on the vertical sidewall of the lateral support 200. A lifting frame 320 is slidably installed on the longitudinal guide rail 310. The lifting frame 320 moves up and down along the longitudinal guide rail 310 via the extension and retraction control of the side-mounted lifting strut 330. A translation guide rail 321 is fixedly mounted on the crossbeam of the lifting frame 320. A position-adjustable top-filling module 800 is slidably mounted on the translation guide rail 321 via an adjusting platform 810. The adjusting platform 810 is driven by the translation strut 820 to slide horizontally along the translation guide rail 321. A top-mounted adjusting strut 830 is fixedly installed at the upper end of the adjusting platform 810. The extended end of the top-mounted adjusting strut 830 points vertically downwards, and a filling cover 840 is fixedly installed at its bottom.

[0031] The vertical position of the dispensing module is adjusted via the longitudinal guide rail 310 and the side-mounted lifting support rod 330, while the horizontal adjustment is achieved in conjunction with the translation guide rail 321, allowing the dispensing cover 840 to be precisely aligned with the sealing opening of different end cap models. The side-mounted lifting support rod 330 uses an electrically controlled screw slide module with a stroke adjustment range of 0–200 mm and a positioning accuracy of ±0.05 mm. The translation support rod 820 uses an electrically controlled push rod with a stroke range of 0–150 mm and a positioning accuracy of ±0.1 mm.

[0032] An external dispensing tube 880 is installed at the upper end of the potting housing 840. The external dispensing tube 880 is connected to an external glue supply system (such as a precision metering pump) to inject the vacuum-degassed potting compound into the annular guide groove 841. An embedded electric heating element 842 is installed inside the annular guide groove 841 to preheat and maintain the potting compound at its optimal flow temperature (typically 40–60°C). The embedded electric heating element 842 is independently controlled by a PID temperature control module with a temperature control accuracy of ±1°C.

[0033] The dispensing assembly 850 includes an annular sealed housing 851 and a dispensing nozzle 852. The annular sealed housing 851 is a hollow annular structure that slides into the annular dispensing groove 841, and the two are sealed with an O-ring. A conical dispensing nozzle 852 is integrally formed at the lower end of the annular sealed housing 851. The dispensing opening at the lower end of the nozzle 852 is an annular slit with a width of 0.3–0.8 mm. An annular toothed groove 853 is formed on the outer arc-shaped surface of the annular sealed housing 851. A top-mounted adjusting motor 870 is fixedly mounted on the upper end of the dispensing housing 840. The output shaft of the top-mounted adjusting motor 870 is connected to a top-mounted adjusting gear 871 via a reducer. The top-mounted adjusting gear 871 passes inside the dispensing housing 840 and meshes with the annular toothed groove 853. The top-mounted adjusting motor 870 is a servo motor that drives the annular sealed cover 851 to rotate within the annular adhesive guide groove 841, causing the dispensing nozzle 852 to move circumferentially relative to the end cap cavity, achieving uniform annular adhesive injection. The rotation speed of the annular sealed cover 851 is controlled by a PLC and can be adjusted within the range of 0.5–5 r / min according to the end cap diameter and the viscosity of the potting adhesive, ensuring that the potting adhesive forms a uniform annular adhesive layer within the end cap cavity. A removable protective sleeve 860 is also installed at the lower end of the potting cover 840 to prevent the adhesive from flowing towards the center of the motor assembly during the potting process.

[0034] The top mounting bracket 500 is mounted above the main conveying frame 100 via a first rotating bracket 400. The first rotating bracket 400 consists of a longitudinal guide cylinder 410, a longitudinal synchronous shaft 420, a rotating adjustment frame 430, and an electrically controlled worm gear assembly 440. The longitudinal guide cylinder 410 is fixedly mounted on the side wall of the main conveying frame 100, and the longitudinal synchronous shaft 420 is inserted into the longitudinal guide cylinder 410 and can slide axially. One end of the longitudinal synchronous shaft 420 is fixedly connected to the rotating adjustment frame 430, and the other end is driven by the electrically controlled worm gear assembly 440, enabling the rotating adjustment frame 430 to swing horizontally around the axis of the longitudinal synchronous shaft 420. The top mounting bracket 500 is fixedly mounted on the rotating adjustment frame 430, and a top suction plate 530 is mounted on its lower end via a top lifting support rod 510. The top suction plate 530 includes a suction cup 531, a flexible guide tube 532, and an electrically controlled air pump 533. The suction cup 531 is made of silicone and has an annular sealing rib on its inner surface. An electrically controlled vacuum pump 533 is connected to the inside of the suction cup 531 via a flexible guide tube 532. The end cap is pre-stacked on the outside, and then the first rotating bracket 400 rotates the suction cup 531 outwards onto the uppermost end cap. The top lifting support rod 510 controls its descent. When the suction cup 531 adheres to the upper surface of the end cap, the electrically controlled vacuum pump 533 starts to create negative pressure, adsorbing and lifting the end cap. The first rotating bracket 400 then swings to transfer the end cap to a subsequent station in the glue-filling process. After glue filling, the motor assembly is moved to the lower end of the end cap. The top lifting support rod 510 then extends to press the end cap against the upper opening of the motor assembly. Under the pressure, the end cap releases from the upper opening of the motor assembly, completing the installation.

[0035] The bottom mounting bracket 700 is installed below the main conveying frame 100 via a second rotating bracket 600, the structure of which is the same as that of the first rotating bracket 400. A bottom heat treatment module 900 is mounted on the upper end of the bottom mounting bracket 700 via a bottom lifting support rod 710. The bottom heat treatment module 900 includes an adjusting base 910, a bottom sealing cylinder 920, an electric fan 930, a built-in heating cylinder 940, and an impact ball 950. The adjusting base 910 is fixedly installed on the extended end of the bottom lifting support rod 710, and the bottom sealing cylinder 920 is fixedly installed on the adjusting base 910. The bottom sealing cylinder 920 is a cylindrical structure with openings at both ends, and the electric fan 930 is fixedly installed inside. The built-in heating cylinder 940 is a hollow cylindrical structure, with heating wires installed inside, and the heating temperature of the heating wires is controlled by an external thermostat. One end of the built-in heating cylinder 940 is coaxially connected to the rotating end of the electric fan 930 via a coupling, and the motor of the electric fan 930 drives the built-in heating cylinder 940 to rotate synchronously. Two impact balls 950, made of steel, are hinged to the side wall of the built-in heating cylinder 940. When the built-in heating cylinder 940 rotates intermittently, the impact balls 950 are thrown outward under the action of centrifugal force, periodically impacting the inner wall of the bottom sealing cylinder 920, generating vibration.

[0036] The bottom heat treatment module 900 is raised when the upper potting module 800 descends, closing the lower opening of the motor assembly to prevent the glue from falling off. Then, the built-in heating cylinder 940 is inserted into the center of the motor assembly, while the adjusting base 910 and the bottom sealing cylinder 920 form a bottom sealing structure.

[0037] The electrical control system of this invention uses a PLC as the core controller and is equipped with a human-machine interface touch screen for parameter setting and status monitoring. The PLC has four PID control loops: the first loop controls the temperature of the embedded electric heating element 842, the second loop controls the heating temperature of the built-in heating cylinder 940, the third loop controls the speed of the precision metering pump of the glue supply system to adjust the glue dispensing volume, and the fourth loop controls the speed of the electric fan 930 to adjust the hot air circulation intensity. The PID controller uses a positional PID algorithm with a sampling period of 100ms. The proportional coefficient Kp, integral time Ti, and derivative time Td are independently tuned according to the response characteristics of each controlled object.

[0038] The working process and automatic control principle of the device are as follows: Step 1, Loading Stage: The operator places the motor assembly to be filled at the starting end of the conveyor belt 110, arranging the motor assemblies before conveying them on the conveyor belt 110. The conveyor belt 110 is driven by a variable frequency speed-regulating motor controlled by a PLC. A photoelectric sensor detects the end cap position signal, and the PLC controls the start, stop, and running speed of the conveyor belt 110 based on the sensor feedback signal, ensuring that the motor assemblies reach the arc-shaped transfer position at a fixed interval and speed.

[0039] Step 2, Transfer Stage: When the end cap reaches the transfer position of the arc section, the position sensor outputs a signal to the PLC. The PLC sends a pulse command to the regulating motor 123, driving the annular regulating frame 122 to slide along the arc guide rail 121 to the end of the conveyor belt 110. After the position sensor detects that the motor assembly is in place, the regulating motor 123 then drives the annular regulating frame 122 in the opposite direction to move the motor assembly along the arc guide rail 121 to the glue dispensing station. During the movement, the end cap rotates about 90 degrees with the annular regulating frame 122, changing from a horizontal posture to a vertical posture or the required glue dispensing posture.

[0040] Step 3, Adhesive Injection Stage: After the motor assembly arrives at the adhesive injection station, the PLC drives the adhesive injection cover 840 to descend above the motor assembly via the side-mounted lifting support rod 330, maintaining a set distance (usually 2-5mm) between the adhesive injection nozzle 852 and the inner cavity of the motor assembly. The translation support rod 820 drives the adjustment platform 810 to make slight lateral adjustments along the translation guide rail 321, ensuring that the adhesive injection nozzle 852 is aligned with the center of the inner cavity of the motor assembly. This is pre-programmed. After positioning, the PLC starts the precision metering pump, and the potting compound enters the annular guide groove 841 through the external dispensing tube 880, and then flows evenly out of the adhesive injection nozzle 852 through the annular sealed cover 851. The annular sealed cover 851 is rotated by the top-mounted adjusting motor 870, allowing the adhesive to be evenly injected into the inner cavity of the motor assembly. At the same time, the embedded electric heating element 842 maintains the temperature of the potting compound within the optimal flow range. The PLC calculates the total amount of adhesive injected based on the end cap volume and the density of the potting compound. It precisely controls the amount of adhesive injected by controlling the running time of the metering pump, with an injection accuracy of ±0.5%. When the amount of adhesive injected reaches the set value, the PLC shuts off the adhesive supply system, and the side-mounted lifting support rod 330 drives the potting cover 840 to rise and reset.

[0041] Before applying the adhesive, the PLC sends a command to the bottom lifting support rod 710, driving the bottom heat treatment module 900 to rise to the bottom of the end cover, so that the upper opening of the bottom sealing cylinder 920 fits against the lower surface of the end cover to form a sealed cavity. The PLC starts the electric fan 930 and the built-in heating cylinder 940. The heating temperature of the built-in heating cylinder 940 is controlled by PID closed-loop, and the electric fan 930 forces hot air to circulate into the sealed cavity to heat the inside of the motor assembly. At the same time, the motor of the electric fan 930 drives the built-in heating cylinder 940 to rotate, and the impact ball 950 periodically impacts the inner wall of the bottom sealing cylinder 920 under the action of centrifugal force, generating vibrations with a frequency of 10-50Hz. The vibration is transmitted to the motor assembly through the bottom sealing cylinder 920, so that the potting adhesive inside the motor assembly is evenly spread and air bubbles are eliminated. After completion, the PLC stops heating, and the fan dissipates heat to facilitate subsequent curing. After curing, after applying glue to the upper opening of the motor assembly, the adjustable top glue-pouring module 800 is raised, and the bottom heat treatment module 900 is lowered and reset. Then, the electrically controlled rotating frame 120 moves the motor assembly to the end cap pre-adsorbed by the top adsorption plate 530, and then the end cap is pressed and fixed to the upper opening of the motor assembly to complete the assembly.

[0042] The above three steps are carried out in parallel under the unified control of PLC: the conveyor belt 110 continuously carries motor components, the electrically controlled rotating frame 120 simultaneously receives the previous motor component and transfers the next motor component to the glue-filling station, the glue-filling module continuously injects glue, the curing station processes in a cycle, and the adsorption plate continuously loads and unloads end caps. The timing of each station is coordinated by the PLC, so that the end caps are continuously produced at a rate of 60-120 pieces / hour.

[0043] The potting compound is a two-component epoxy or polyurethane resin. Component A is the resin matrix, and component B is the curing agent. The two are mixed in a set ratio (usually 2:1 to 4:1) using a precision metering pump before being supplied. The supply system is equipped with an online static mixer and a vacuum degassing device to ensure uniform mixing without air bubbles. The viscosity range of the potting compound is 500–3000 mPa·s (25℃), the Shore hardness after curing is D60–D85, and the volume resistivity is greater than 1×10⁻⁶. 14 Ω·cm. Users can select different types of potting compound materials according to the operating temperature and protection level requirements of the end cap.

[0044] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical spirit of the present invention. The technical scope of the present invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A continuous potting device for end caps of brushless DC motors, comprising a main conveyor frame (100), a conveyor belt (110) for mounting the transverse section of the main conveyor frame (100), and an electrically controlled rotating frame (120) mounted on the arcuate section of the main conveyor frame (100), characterized in that: A height-adjustable top bracket (300) is installed above the main conveying frame (100) via a side bracket (200). A top mounting bracket (500) is installed above the main conveying frame (100) via a first rotating bracket (400). A bottom mounting bracket (700) is installed below the main conveying frame (100) via a second rotating bracket (600). A position-adjustable top glue-filling module (800) is provided at the lower end of the crossbeam of the height-adjustable top bracket (300). A top-mounted adsorption plate (530) is installed at the lower end of the top mounting bracket (500) via a top lifting support rod (510). A bottom heat treatment module (900) is installed at the upper end of the bottom mounting bracket (700) via a bottom lifting support rod (710).

2. The continuous potting device for end caps of brushless DC motors according to claim 1, characterized in that: The height-adjustable top support (300) includes a longitudinal guide rail (310) mounted on the side wall of the side support (200), a lifting frame (320) slidably mounted on the longitudinal guide rail (310), and a side-mounted lifting strut (330) mounted on the side wall of the side support (200). The side-mounted lifting strut (330) controls the lifting frame (320) to rise and fall along the longitudinal guide rail (310) by telescopic control.

3. The continuous potting device for end caps of brushless DC motors according to claim 1, characterized in that: The first rotating bracket (400) and the second rotating bracket (600) are both composed of a longitudinal guide cylinder (410) fixedly installed on the side wall of the main conveying frame (100), a longitudinal synchronous shaft (420) inserted inside the longitudinal guide cylinder (410), a rotating adjustment frame (430) axially fixed to one end of the longitudinal synchronous shaft (420), and an electric control worm gear assembly (440) installed at the other end of the longitudinal synchronous shaft (420).

4. The continuous potting device for end caps of brushless DC motors according to claim 1, characterized in that: The lower surface of the arc section of the main conveying frame (100) is equipped with an arc-shaped guide rail (121). The electrically controlled rotating frame (120) includes an annular adjustment frame (122) that is slidably installed inside the arc-shaped guide rail (121) and an adjustment motor (123) installed on the arc-shaped guide rail (121). The adjustment motor (123) is driven by an adjustment gear (124) on the adjustment shaft that passes through the arc-shaped guide rail (121) and meshes with the annular tooth groove (125) on the annular adjustment frame (122).

5. A continuous potting device for end caps of brushless DC motors according to claim 2, characterized in that: The lifting frame (320) is fixedly mounted with a translation guide rail (321) on its crossbeam. The position-adjustable top glue-filling module (800) includes an adjustment platform (810) slidably mounted on the translation guide rail (321), a translation support rod (820) mounted on the adjustment platform (810), a top adjustment support rod (830) fixed on the upper end of the adjustment platform (810), a glue-filling cover (840) mounted on the bottom of the extended end of the top adjustment support rod (830), a glue-dispensing assembly (850) movably mounted on the lower end of the glue-filling cover (840), a detachable protective sleeve (860) mounted on the lower end of the glue-filling cover (840), a top adjustment motor (870) mounted on the upper end of the glue-filling cover (840), and an external glue-filling tube (880) mounted on the upper end of the glue-filling cover (840).

6. A continuous potting device for end caps of brushless DC motors according to claim 5, characterized in that: The lower surface of the glue-filling cover (840) is provided with an annular glue-guiding groove (841) that is connected to the external glue-filling tube (880).

7. A continuous potting device for end caps of brushless DC motors according to claim 6, characterized in that: The dispensing assembly (850) includes an annular sealed cover (851) that is slidably inserted into the annular guide groove (841) and an integral dispensing nozzle (852) fixed at the lower end of the annular sealed cover (851). Annular toothed grooves (853) are provided on the outer arc surface of the annular sealed cover (851). The top-mounted adjusting motor (870) drives the annular sealed cover (851) to rotate and adjust inside the annular guide groove (841) by meshing with the annular toothed groove (853) through the top-mounted adjusting gear (871).

8. A continuous potting device for end caps of brushless DC motors according to claim 1, characterized in that: The top-mounted suction cup (530) includes a suction cup (531) axially fixed to the extended end of the top lifting support rod (510) and an electrically controlled air pump (533) connected to the inside of the suction cup (531) through a flexible guide tube (532).

9. A continuous potting device for end caps of brushless DC motors according to claim 1, characterized in that: The bottom heat treatment module (900) includes an adjustment base (910) installed at the extended end of the bottom lifting support rod (710), a bottom sealing cylinder (920) installed on the adjustment base (910), an electric control fan (930) installed inside the bottom sealing cylinder (920), an internal heating cylinder (940) coaxially connected to the rotating end of the electric control fan (930), and an impact ball (950) hinged to the side wall of the internal heating cylinder (940).

10. A continuous potting device for end caps of brushless DC motors according to claim 7, characterized in that: An embedded electric heating element (842) is installed on the inner side of the annular guide groove (841) at the position corresponding to the annular toothed groove (853).

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