电机换向器轴 / Motor Commutator Shaft
电机换向器轴
电机换向器轴是新能源汽车辅助电机及各类微特电机中的核心传动部件，其同轴度、尺寸精度与表面质量直接决定了电机在高速运转下的平稳性与使用寿命。昆山图达讯电子科技有限公司采用416不锈钢（416 Free-Machining Stainless）为基材，依托高精度走心机纵切与车铣复合工艺，为您提供微米级精度的换向器轴定制加工服务。
凭借近三十年的精密加工经验与60余台进口走心机的强大产能，我们严格控制换向器段的磨削预留量与轴承位的表面粗糙度，确保每一根轴件都能完美匹配下游电机的装配需求，助力客户提升终端产品的整体性能与可靠性。
关键参数
表格
| 参数项 | 规格/说明 |
|---|---|
| 材质 | 416不锈钢（416 Free-Machining Stainless） |
| 加工工艺 | 走心机连续纵切 + 双主轴对接加工 + 车铣复合 |
| 加工直径范围 | Φ4mm – Φ10mm |
| 典型长度 | 20mm – 50mm |
| 公差等级 | ±0.005mm (IT6) |
| 表面粗糙度 | Ra0.4 – Ra0.8 |
| 表面处理 | 镀镍 |
| 应用领域 | 新能源汽车辅助电机、雨刮电机、电动助力转向系统等 |
| 最小起订量 | 1000件起，支持打样 |
| 打样周期 | 3-5天（具体视图纸复杂度而定） |
产品特点与走心机工艺优势
- 双主轴对接保障极致同轴度：采用走心机双主轴同步加工技术，一次装夹完成车削、铣削与对接，有效消除二次装夹误差，确保换向器段与轴承位的极高同轴度，保障电机高速运转平稳无异响。
- 精准的磨削余量控制：针对换向器段的特殊工艺要求，加工中精密预留0.05mm的磨削余量。这不仅保证了后续热处理及精密磨削工序的一致性，更提升了最终成品的表面硬度与耐磨性能。
- 轴承位超精表面成型：轴承配合位采用精车工艺，表面粗糙度严格控制在Ra0.4–Ra0.8。超光滑的表面大幅降低了电机运转时的摩擦阻力与温升，延长轴承使用寿命。
- 416不锈钢材质赋能：选用416马氏体不锈钢，具备优良的自润滑性能与切削加工性。在满足高强度与耐腐蚀要求的同时，有效降低加工硬化风险，确保大批量生产的尺寸稳定性。
典型应用
- 新能源汽车辅助电机：用于电子水泵、电子油泵及热管理系统电机，满足新能源车高转速、长寿命的严苛要求。
- 汽车雨刮电机轴：提供高扭矩传输与抗疲劳性能，确保雨刮系统在极端天气下的稳定运行。
- 电动助力转向（EPS）小轴：作为转向系统的关键微型传动件，保障转向手感精准、响应迅速且运行静谧。
公司实力与品质保障
昆山图达讯电子科技有限公司始创于1998年，深耕精密走心机加工近三十年。公司拥有60余台进口走心机（品牌涵盖西铁城 Citizen、津上 Tsugami、斯大 Star），日产能高达50万件，并已通过 IATF16949 与 ISO9001 双体系认证。我们以微米级的加工精度、稳定的量产能力和严苛的质量管控，为全球汽车、医疗、通信及工业自动化领域的客户提供卓越的精密零部件解决方案。
获取定制报价与技术支持：
- 官网：www.tudasyn.com
- 邮箱：yty@tudasyn.com
- 电话：18913105795
Motor Commutator Shaft
The motor commutator shaft is a critical transmission component in new energy vehicle (NEV) auxiliary motors and various micro-motors. Its coaxiality, dimensional accuracy, and surface quality directly determine the stability and service life of the motor during high-speed operation. Kunshan Tudasyn Electronic Technology Co., Ltd. utilizes 416 Free-Machining Stainless Steel as the base material, relying on high-precision Swiss-type CNC longitudinal cutting and turn-mill composite processes to provide you with customized micrometer-level precision commutator shaft machining services.
With nearly 30 years of precision machining experience and the robust production capacity of over 60 imported Swiss-type CNC machines, we strictly control the grinding allowance of the commutator segment and the surface roughness of the bearing seats. This ensures that every shaft perfectly matches the assembly requirements of downstream motors, helping clients enhance the overall performance and reliability of their end products.
Key Specifications
表格
| Parameter | Specification / Description |
|---|---|
| Material | 416 Free-Machining Stainless Steel |
| Machining Process | Swiss-type continuous longitudinal cutting + Dual-spindle synchronous machining + Turn-mill composite |
| Machining Diameter | Φ4mm – Φ10mm |
| Typical Length | 20mm – 50mm |
| Tolerance | ±0.005mm (IT6) |
| Surface Roughness | Ra0.4 – Ra0.8 |
| Surface Treatment | Nickel Plating |
| Applications | NEV auxiliary motors, wiper motors, electric power steering (EPS) systems, etc. |
| Minimum Order | 1,000 pcs, prototyping supported |
| Prototyping Lead Time | 3-5 days (depending on drawing complexity) |
Features & Swiss-Type CNC Advantages
- Ultimate Coaxiality via Dual-Spindle Synchronous Machining: Utilizing dual-spindle synchronous processing technology, turning, milling, and back-working are completed in a single clamping. This effectively eliminates secondary clamping errors, ensuring extremely high coaxiality between the commutator segment and bearing seats, which guarantees smooth and noise-free high-speed motor operation.
- Precision Grinding Allowance Control: Addressing the specific process requirements of the commutator segment, a precise grinding allowance of 0.05mm is reserved during machining. This not only ensures consistency in subsequent heat treatment and precision grinding processes but also enhances the surface hardness and wear resistance of the final product.
- Ultra-Fine Bearing Seat Surface Finishing: The bearing mating surfaces are finished using precision turning, with surface roughness strictly controlled at Ra0.4–Ra0.8. This ultra-smooth surface significantly reduces friction resistance and temperature rise during motor operation, extending bearing life.
- Material Advantages of 416 Free-Machining Stainless Steel: The selected 416 martensitic stainless steel offers excellent self-lubricating properties and machinability. While meeting requirements for high strength and corrosion resistance, it effectively reduces the risk of work hardening, ensuring dimensional stability in mass production.
Typical Applications
- NEV Auxiliary Motors: Used in electronic water pumps, electronic oil pumps, and thermal management system motors, meeting the strict requirements for high RPM and long lifespan in new energy vehicles.
- Automotive Wiper Motor Shafts: Provides high torque transmission and fatigue resistance, ensuring the stable operation of wiper systems in extreme weather conditions.
- Electric Power Steering (EPS) Pinions/Shafts: As a critical micro-transmission component in the steering system, it ensures precise steering feel, rapid response, and quiet operation.
Company Capability & Quality Assurance
Kunshan Tudasyn Electronic Technology Co., Ltd., founded in 1998, has been deeply engaged in precision Swiss-type CNC machining for nearly 30 years. The company owns over 60 imported Swiss-type CNC machines (brands including Citizen, Tsugami, and Star) with a daily production capacity of up to 500,000 pieces. We are certified with both IATF16949 and ISO9001 dual management systems. With micrometer-level machining precision, stable mass production capabilities, and strict quality control, we provide superior precision component solutions for global clients in the automotive, medical, telecommunications, and industrial automation sectors.
Get a Custom Quote & Technical Support:
- Website: www.tudasyn.com
- Email: yty@tudasyn.com
- Tel: 18913105795
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