Modelling of assembly error and tolerance optimization for motor based on polyhedral model and thermal deformation...

Area of Science:

• Mechanical Engineering
• Manufacturing Science
• Automotive Engineering

Background:

• The air gap between stator and rotor is critical for electric motor performance.
• Machining deviations accumulate, affecting the air gap size and motor function.
• Thermal loads during operation introduce additional complexity to assembly errors.

Purpose of the Study:

• To develop a method for analyzing and optimizing electric motor assembly errors, considering thermal deformation.
• To establish a polyhedral model for representing deviation transfer paths.
• To minimize processing and quality loss costs through tolerance optimization.

Main Methods:

• Development of a polyhedral model for assembly deviation transfer path analysis.
• Incorporation of thermal deformation effects using Minkowski summation and intersection operations.
• Application of a multi-objective particle swarm optimization algorithm for tolerance optimization.

Main Results:

• The study successfully determined cumulative assembly errors, including the impact of thermal deformation.
• A multi-objective tolerance optimization model was established with processing and quality loss costs.
• Optimized tolerances for critical motor components were identified, considering thermal effects.

Conclusions:

• The proposed method provides a novel theoretical framework for electric motor assembly error analysis.
• Incorporating thermal deformation is essential for accurate tolerance optimization.
• The findings offer a valuable technical reference for improving electric motor design and manufacturing.