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Verification of insulation integrity and dielectric strength to confirm electrical safety under intended operating conditions before production release.
Evaluate motor performance (speed, current, output) under no-load and representative tool load conditions to verify design and assembly before mass production.
Verify starting performance and overload tolerance under load and sudden resistance increase, ensuring reliable motor startup and stable operation in expected conditions.
Simulation of jamming and stall scenarios (e.g., cutting jam / debris blockage) to verify motor tolerance under abnormal operating conditions and the reliability of recovery operation prior to production approval.
Assess temperature rise under duty cycles with short operating periods, frequent start–stop, and high peak loads to confirm thermal design suitability before mass production.
Repeated on–off cycling to evaluate motor reliability under frequent switching conditions representative of real application usage, ensuring durability prior to production release.
Evaluation of noise and vibration behavior under representative operating conditions to identify potential mechanical or structural risks before mass production.
Verify key external features and dimensions (outer diameter, shaft, mounting interface, assembly) to ensure design conformity and readiness for consistent production.
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Frequent cutting jams caused stall events and overheating. Battery runtime dropped under real grass load, and vibration increased noise after extended use.
Re-matched a BLDC-based platform for higher efficiency and better peak torque margin, improved thermal path for intermittent heavy duty, and reinforced mechanical robustness (balance + bearing strategy + mount damping) to stabilize vibration and noise.
Loaded start and overload tolerance verified under resistance spikes; stall & recovery validated under jam scenarios; thermal stability verified under intermittent duty cycles; noise & vibration evaluated before production release.
Let’s first look at three points: load intensity, frequency of use, and cost boundary. Choose Brushed DC for low duty cycle and cost sensitivity; Choose BLDC for efficiency, low noise, and lifespan; Long term continuous, wired heavy-duty environment, Induction/AC is more stable. Platform selection should serve the system objectives, rather than solely focusing on motor types.
We not only look at rated points, but also establish continuous operating condition models based on real loads and duty cycles. Under the worst voltage, highest ambient temperature, and worst heat dissipation conditions, perform long-term steady-state operation, record temperature rise trends rather than instantaneous values, and verify whether the thermal equilibrium point is below the material and insulation limits.
Seize three moments: starting moment, stuck/stuck rotor, and extreme working condition switching. Describe peak events using maximum current, minimum speed, and duration, rather than rated points. The peak definition is clear, and the platform and protection strategy naturally converge.
Don’t just increase the airflow. Firstly, analyze the sources and pathways of dust, and then control dust accumulation through diversion, isolation, settling zones, and cleanable structures. Verify that the temperature rise trend should be observed under the operation of electrified dust accumulation to ensure that long-term heat dissipation is still controllable.
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