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With the advancement of high-voltage and high-power automotive drive motors, the three-bearing structure is generally adopted to meet the requirements of heavy loads and minimal axial play control. The three-bearing structure refers to the adoption of two sets of bearings at the drive end of the motor and one set at the non-drive end, which can enhance the bearing capacity and service life of the bearings at the shaft extension end. During the bearing selection process for motors, bearing suppliers often emphasize the minimum and maximum preload. They point out that improper preload may lead to NVH (Noise, Vibration, Harshness) issues or bearing damage. Therefore, wave springs are typically installed between the bearings and end caps to achieve preload.
When the motor is subjected to impacts or vibrations during operation, the multi-layer wave springs can absorb part of the energy, mitigating the impact on the bearings and extending their service life. Additionally, the elastic properties of the wave springs can accommodate the thermal expansion and contraction as well as minor axial displacement of the motor under different operating conditions, preventing bearing damage caused by excessive axial force. Furthermore, the multi-layer wound wave springs can provide a relatively precise preload, reducing bearing clearance during operation, enhancing bearing stiffness and rotational accuracy. By applying an axial preload to the bearing outer race through the wave springs, noise can be reduced, thereby ensuring stable motor operation and improving NVH.
Motor Bearing Preload: In electric vehicle motors, bearings are crucial components supporting the rotor and reducing friction. To ensure stability during high-speed rotation, appropriate preload is necessary. Wave washers, with their compact structure and high elastic precision, are ideal for achieving this. By placing wave washers between the inner and outer races of the bearings, uniform preload is provided, preventing excessive axial displacement or vibration during operation.
Gearbox Vibration Reduction: In the gearboxes of electric drive systems, gear meshing generates vibrations and noise. To mitigate these adverse effects, wave springs can be installed at key locations within the gearbox. The flexible properties of wave springs absorb part of the vibration energy, converting it into elastic potential energy and reducing vibration amplitude. Simultaneously, they offer damping effects, further inhibiting vibration propagation.
Sensor and Actuator Installation: In electric drive systems, sensors and actuators are vital components for monitoring and controlling motor operating conditions. To ensure stable and reliable operation, these components must be securely mounted in appropriate positions. Wave springs serve as mounting washers or supports, compensating for installation tolerances and errors through elastic deformation, ensuring precise installation and positioning of the components.
Electromagnetic Clutches and Brakes: In electric drive systems requiring rapid response and precise control, electromagnetic clutches and brakes are indispensable. Wave springs are commonly used in the pressing mechanisms of these components, leveraging their high elasticity to provide stable pressing force, ensuring reliable operation. Additionally, the spring plates absorb shocks and vibrations to some extent, prolonging the service life of clutches and brakes.
Axial Fixing of Motor Stators: In certain motor designs, wave springs are employed to ensure that stator components do not experience axial displacement or loosening during high-speed rotation. The high elastic precision and compact structure of wave springs enable precise control of the stator's axial position while providing necessary preload to prevent loosening.
These application examples demonstrate the versatility and significance of wave springs in electric drive systems. With the continuous development and innovation of electric drive technology, the application areas of wave springs will continue to expand and deepen.
