In the wave of iterative upgrading towards high power and high performance in the small home appliance industry, the design margin of product core indicators is constantly being compressed, while the market's requirements for research and development efficiency, cost control, and production consistency continue to rise. As a technology-based enterprise that has been deeply involved in the field of electric motors for many years, Power Motor's R&D department has always adhered to the research and development philosophy of "mature processes as the basis, performance optimization as the core, and cost control as the key". While meeting the ultimate product indicators, Power Motor provides customers with motor solutions that are both competitive and reliable in the market, especially in EMC performance optimization, forming a unique technological advantage.

EMC performance is the "passport" for motors to enter mainstream markets such as Europe and Japan, and must strictly comply with international standards such as EN 55014. We deeply recognize that the root cause of motor EMC problems must be traced back to the design source, rather than being remedied afterwards. With a profound understanding of the core mechanism of motors and practical experience in over a thousand products, we have established a full process EMC control system from design simulation, component matching to factory verification, ensuring that each motor passes multidimensional testing before sending samples, reducing customer product development risks from the source.

1、Structural optimization: Building the cornerstone of EMC performance with precision design:

The rationality of the mechanical structure of the motor directly determines the stability of EMC performance. Power Motor relies on a professional structural simulation team and precision manufacturing experience to form a standardized and customized solution in the design of key components. For example, in the design of the coordination between carbon brushes and carbon brush boxes, single parameter dependence is abandoned, and dynamic gap matching schemes are developed through big data analysis of the operating characteristics of motors of different power levels. This not only avoids the problem of life decay caused by small gaps, but also eliminates EMC anomalies caused by large gaps, achieving a precise balance between life and electromagnetic compatibility.

In the design of motor shaft system and commutator, Power Motor breaks through the limitations of traditional machining, optimizes the machining process chain and precision control standards, and controls the roundness and runout errors of the commutator from the source. In response to the concentricity problem that is prone to occur with traditional step shafts, an integrated shaft system design concept is adopted, combined with dedicated processing equipment to ensure shaft system accuracy, fundamentally solving the problems of abnormal sparks and EMC non conformance caused by mechanical vibration, while effectively reducing the customer's subsequent assembly costs.

2、Carbon brush system optimization: improving EMC consistency through innovative design

The carbon brush running in process is a key link that affects the EMC stability of the motor. The R&D department of Power Motor has accumulated a large amount of experimental data and found significant differences in the contact characteristics of carbon brushes in motors of different power levels. Based on this, a differentiated carbon brush structure optimization scheme has been developed. Innovatively optimizing the carbon brush contact structure to address the common issues of unstable running in and EMC fluctuations in high-power motors, reducing the initial contact area through special shape design, effectively suppressing spark generation, and significantly improving the stability of EMC performance. In higher power level motor products, high-power motors, carbon brush offset and high current effects can cause unstable carbon brush running in, resulting in unstable EMC. Some motors in the same batch may have EMC non-compliance; Further upgrade of the solution is needed to combine the optimization of carbon brush structure with edge processing, ensuring a perfect fit between carbon brush and commutator through multi-dimensional structural adjustment, completely solving the industry pain points of insufficient EMC margin and poor consistency in similar products. These optimization schemes are all based on the testing platform independently developed by Power Motor, and have achieved precise control of EMC indicators without affecting the core performance of the motor.

3、Full chain service: Empowering customers with systematic thinking to enhance value

The EMC performance of a motor is the result of multiple factors working together. In addition to the design of core components, it is closely related to the matching of capacitors, inductors, and other components, as well as the design and internal wiring of customer products. To this end, Power Motor has established a full chain service model of "motor design+system adaptation": not only providing customers with high-performance motor products, but also equipping a professional technical team to provide EMC system optimization suggestions for customers. Through cross domain technical collaboration, Power Motor helps customers quickly complete product integration and testing verification.

With its technological accumulation and service innovation in the EMC field, Power Motor has become a strategic partner for many well-known small home appliance enterprises. In the future, Power Motor will continue to focus on breakthroughs in core motor technologies, relying on digital research and development platforms and intelligent production systems, continuously improving the electromagnetic compatibility and comprehensive competitiveness of products, and injecting core power into the high-quality development of the industry.

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Note:‌ This article is contributed by Power Motor Research and Development Department