1. Integrated processing of high-precision end face seal and bearing support structure

① The multi-stage composite seal structure is precisely formed

Using customized molding tools and five-axis linkage engraving technology, the precision machining of multiple sealing features such as radial O-ring grooves, end face sealing gasket grooves, labyrinth dust-proof structures and rotary shaft lip seal mounting holes of the end caps is completed in one clamping, and the size tolerance of the sealing groove is controlled at ±0.015mm, and the rounded corners are smooth and burr-free, providing reliable protection for IP65/IP67/IP69K and other high protection levels.

② High-precision bearing holes are machined synchronously with the output interface

On the precision CNC lathe or turning-milling composite center, the bearing mounting hole, output flange connection surface and

The processing of the fixed stop is to ensure that the bearing bore is coaxial with the output flange Degree ≤ Φ0.008mm (≤Φ0.015mm), end face runout ≤0.005𝗆𝗆 , providing accurate terminal support for the transmission system.

③ Integrated sensor and cable interfaces are precision-manufactured

Precision-machined built-in encoder/Hall sensor mounting cavity, signal connector interface and multi-channel waterproof cable gland mounting hole ensure the positioning accuracy and sealing reliability of the electrical interface to meet the needs of modular quick plugging.

2. Lightweight reinforced structure and dynamic performance optimization

①  Topology optimization of rib plate and thin-walled structure anti-deformation processing

According to the results of finite element analysis, high-speed milling technology is used to accurately realize the internal asymmetric stiffener and optimal material distribution structure, which minimizes the weight (weight control accuracy) while ensuring the overall rigidity and impact resistance of the end cap ±1% ).

② Local reinforcement of the high-load bolted connection area

For the key stressed areas such as the perimeter of the output flange bolt hole, the end cap and the connection surface of the body, the local material thickening design and processing are carried out, and the threaded hole extrusion strengthening or sleeve treatment is implemented to greatly improve the fatigue strength and fretting wear resistance of the connection.

③ Dynamic balance integrated design and deduplication processing

For high-speed rotating output end caps, dynamic balancing adjustment structures (such as de-weighting grooves and counterweight block mounting positions) can be integrated, and component-level dynamic balancing can be realized through precision machining to meet the requirements of low vibration under high-speed operation.

3. Thermal management and surface function integration

① Integrated cooling fins and coolant interface processing

On the motor end cap or high-power consumption end cap, the radial heat dissipation fin or the flat runner that matches the cooling plate is directly processed, and the coolant inlet and outlet threaded interface is precisely machined to achieve efficient active heat dissipation.

② Multi-functional surface treatment is integrated

It provides a variety of surface treatment options such as hard anodizing (thickness 30-50μm, hardness ≥HV400), micro-arc oxidation, Teflon coating, laser marking, etc., to meet the comprehensive needs of corrosion resistance, wear resistance, insulation, and identification at one time.

4. Full-dimensional quality verification and data delivery

① Simulation and measurement verification of sealing performance

Fluid simulation is used to analyze the rationality of the seal structure, and each batch of products is tested for holding pressure or helium mass spectrometry leakage detection at specified pressure (pneumatic/hydraulic) to ensure seal reliability and provide authoritative test reports.

② 3D scanning and assembly simulation

The blue light 3D scanner is used to obtain high-precision point cloud data of the finished end cap, compare and analyze with the customer's original design model, generate 3D chromatographic deviation map, and support virtual assembly verification.

③ Digital full inspection package delivery

Use high-precision coordinate measuring machines, roundness meters, and roughness meters to carry out key dimensions, shape and position tolerances, and sealing surface quality 100% Full inspection, delivery of a complete digital data package including 2D drawing annotation report, 3D deviation map and material certificate.