Promote the development of silent home appliances and take the lead in commercializing resin-encapsulated motors in the world
In 1975, Japan Denco Hi-Tech Electric Co., Ltd. commercialized resin-encapsulated motors for the first time in the world. In the past, steel sheets were used for the motor housing, but in order to meet the demand for quieter motors in washing machines and air conditioners, the practical application of these motors was challenged. By replacing the steel plate casing with a resin casing, the structure can achieve 100% of the damping performance of resin, but there are many issues that need to be solved in the face of mass production. In terms of molding, it was necessary to fill not only the thick-walled part of the casing, but also the gap between the coiled lines of the impregnated paint. In addition, if the position of the parts changes under the pressure of the resin, the specified performance may not be achieved.
It was a bold attempt to replace the motor casing itself with resin. Overcoming technical difficulties, we are the first in the world to commercialize them.
At that time, the flow analysis technology inside the mold was not yet complete, and to a certain extent, it was necessary to repeatedly try to fill the injection mold and then observe the filling degree of the resin, and in this way, the change of the resin inside the mold was analyzed, and the shape of the mold, the position of the nozzle, the temperature control, the pressure of injection molding, and the composition of the resin were optimized. In 1975, the plastic package of the AC motor was realized, and in 1982, the plastic package of the brushless DC motor was also successful. At the same time, the inverter circuit in the plastic casing was successfully built-in.
In addition to magnetic circuits, inverter circuits were introduced into resin, completing the integration. Since the heat conductivity of the resin used exceeds that of air, the heat dissipation performance has been improved, and the resin has been made smaller than before. In recent years, the development of dedicated power ICs for drives, magnetic circuit designs that are optimal for aluminum windings, and dedicated winding machines that can efficiently produce aluminum windings have also taken on the challenge. As a result of its cost competitiveness, it is expanding into overseas markets.
It is such a straight iron core, which uses a self-developed special winding machine for aluminum winding, and uses ferrite magnets instead of rare earth materials to create a magnetic circuit with the same effect, which can make the best use of electromagnetic steel plate materials and reduce assembly costs. These three advantages have also become the focus of attention overseas. At the same time, Europe has begun to regulate the consumption of electricity for home appliances, etc., and Japan Denco Hi-Tech Motor, which specializes in brushless DC motor technology, has a favorable external environment. Resin-encapsulated motors, starting with small motors, have been developed in turn to high-power models, and the current lineup ranges from 10W to 1KW. In the future, the company plans to expand its sales of resin-encapsulated motors in North and South America, including in Europe, as well as in a variety of applications such as water heaters and air purifiers, as well as for air conditioners and washing machines.
A resin encapsulation series that starts with a small motor. Since then, high-power models have been developed in turn, and at present, models ranging from 10W to 1KW are available.
Instructions from R&D personnel
Recently, we are developing brushless DC motors for washing machines. We know that the brushless DC motor has good control, and the operation sequence that achieves it suppresses the noise caused by the turbulent flow of water in the sink, and when combined with the quietness of the motor itself, it creates a washing machine with an excellent quiet effect. In the field of home appliances, silence is the first thing and energy saving is second, so the advantage of holding the asset of brushless DC motors (resin encapsulated) is huge for our company. In recent years, there have been many followers from overseas competitors, but as a leader in resin encapsulated motors, we will continue to develop excellent products by making full use of the technology and know-how we have cultivated over the years.
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