①Double-sided high-precision datum simultaneous processing

The use of precision vertical or horizontal machining center with high-precision flipping fixture ensures that the parallelism of the mounting surface on both sides of the middle cover with the reducer and motor is ≤0.005mm, flatness ≤0.008mm, and surface roughness 𝖱𝖺𝗌𝗈.𝟦μ𝗆 to provide the perfect benchmark for modular assembly.

② Multi-stage sealing tank is precisely formed at one time

Customized molding tools and micro-diameter carving processes are used to complete the precision machining of O-ring static sealing grooves, rotary shaft lip seal mounting holes, and labyrinth dust-proof sealing structures in one clamping. The slot width, slot depth, and fillet tolerances are strictly controlled within ±0.015mm, ensuring the reliable realization of IP65/IP67 and above protection levels.

③Special-shaped wire holes and ventilation valve interfaces are precision machined

Micro milling and precision drilling and reaming processes are used to process the internal sensor cable channel, power supply hole, and micro vent valve mounting threads to balance internal and external air pressure, and the orifice is treated with mandatory R angle to protect the cable and meet EMC requirements.

①Anti-deformation processing of thin-walled ring/special-shaped structures

For the common thin-walled annular or special-shaped structure with reinforcing ribs in the middle cover, the process strategies such as layered symmetrical milling and low-temperature cutting are adopted, and the process stress release is used to effectively control the processing deformation to ensure that the thickness tolerance is ± 0.05mm and the flatness is stable and up to standard.

②Local bearing area enhancement design processing

In key load-bearing parts such as bearing mounting shoulders and high-strength bolting areas, local rigidity and fretting fatigue resistance are significantly improved by locally increasing the thickness of the material, processing profiling stiffeners, or implementing surface rolling reinforcement.

③Lightweight topology is precisely realized

According to the finite element analysis results provided by the customer, the internal asymmetric weight reduction cavity and topology optimization rib plate are precision machined to achieve optimal weight under the premise of ensuring structural strength, and the weight control accuracy reaches ±1%.

①High-speed rotating components are dynamically balanced for deweighting

For mid-covers connecting high-speed rotating components, such as motor shafts, the balancing groove or counterweight mounting position can be integrated and precise-machined to assist in achieving G2.5 or higher dynamic balancing at the component level.

② Integrated heat dissipation channel and thermal interface processing

Internal coolant circulation microchannels or high thermal conductivity material inlay grooves are processed, and the plane that matches the cooling plate/heat sink is precisely machined to ensure that the thermal resistance of interface contact is minimized and the overall heat dissipation efficiency of the joint is improved.

①Detection and control of microscopic topography of sealing surfaces

Use white light interferometer or high-precision profiler to microscopicly inspect the bottom and side of the sealing groove to ensure that there are no machining knife marks, burrs and other defects, and the surface roughness Ra value is uniformly up to standard, ensuring the sealing reliability from the microscopic level.

② Airtightness and functional testing support

According to customer standards, the finished cover can be tested for air pressure or helium mass spectrometry leakage and a test report can be provided. At the same time, it supports trial assembly verification with standard sealing rings and bearings.

③ Digital inspection packet delivery

Use a coordinate measuring machine to carry out all key dimensions, shape and position tolerances, and hole positions of the middle cover 100% Full inspection or SPC control, delivery of complete data packages including 3D chromatographic deviation maps and 2D labeling test reports.