Electromagnetic Optimization Design of High Torque CNC Rotary Table Torque Motor
Publish Time:
2025-07-28 16:34
Source:
In the core components of the five-axis linkage machining center, the electromagnetic performance of the high-torque CNC rotary table torque motor directly affects machining accuracy and dynamic response. With the implementation of the new GB/T 20957.7-2025 standard in 2025, traditional electromagnetic design schemes have exposed common issues such as large torque fluctuations and rapid temperature rise under continuous high-load conditions.
To address the torque fluctuation problem, an optimized solution using a non-uniform air gap combined with a Halbach array can effectively improve the magnetic field distribution. Finite element analysis shows that when the pole arc coefficient is controlled within the range of 0.82-0.85, the cogging torque can be reduced by about 40%. At the same time, adopting a stepped skew slot design for the stator core, combined with the directional magnetization process of rare earth neodymium iron boron magnets, can further suppress torque ripple caused by harmonic magnetic fields.
Regarding temperature rise control, the integrated design of a new oil cooling channel and stator winding shows good results. Measured data indicate that under the same load conditions, the temperature rise of motor windings using three-dimensional spiral cooling pipes can be reduced by 12-15°C compared to traditional water cooling solutions. This design optimizes the matching relationship between coolant flow rate and pipe cross-sectional area through ANSYS Fluent fluid simulation, ensuring temperature stability of electromagnetic components during continuous operation at 2000 rpm.
Electromagnetic compatibility improvement is another technical focus. By establishing a multi-physics coupling model of the rotary table system, it was found that using a layered shielding structure can significantly reduce high-frequency switching noise. Specifically, installing a nanocrystalline alloy shielding layer inside the motor end cover, combined with twisted pair power cables, can control electromagnetic interference intensity to below 70% of the EN 61000-6-4 standard limit.
Practical application cases show that after adopting this optimization scheme in a gantry machining center, the rotary table's positioning error remained stable within ±3 arc seconds under continuous heavy cutting conditions for 8 hours. This is mainly attributed to three improvements brought by electromagnetic parameter optimization: the sinusoidal degree of the air gap magnetic flux density waveform increased to 98%, dynamic stiffness enhanced by 27%, and current harmonic distortion rate reduced to below 5%. These technical indicators have been verified through a 72-hour uninterrupted test by the National Machine Tool Quality Supervision and Inspection Center.
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