Customer Case Study:
On a clear morning, Longsheng Manufacturing's independent website received a new inquiry email. The customer, Kraft Motors GmbH, a German automotive manufacturing company, was developing a new electric vehicle motor and urgently needed some high-precision metal parts for testing. They attached images of the required components, which were complex mechanical parts, including bearing housings, metal gaskets, and sleeves. These parts required extremely tight tolerances and needed to be prototyped and delivered in a short time.

Application Analysis:
Electric vehicle (EV) motors and their complex mechanical components, such as bearing housings, metal gaskets, and sleeves, are crucial for the motor's performance, efficiency, and lifespan. Below is a detailed analysis of these components' roles in EV motors:

1. Bearing Housing

   • Function: A key component that supports the motor shaft, providing a mounting location for the bearing to ensure stable rotation and reduce friction. Since EV motors operate at high speeds, bearing housings must have high precision and wear resistance to avoid vibration or noise during operation.
   • Application Scenarios:
     • High Speed and Low Noise: The bearing housings in EV motors need to withstand high speeds and have excellent shock absorption and noise reduction capabilities. The choice of materials (e.g., aluminum alloy, steel, or composite materials) and machining precision (tolerances within 0.005mm) are crucial for enhancing the durability of the bearing housing.
     • Heat Dissipation: Bearing housings must possess good thermal conductivity to transfer heat to the cooling system, preventing overheating during motor operation.

2. Metal Gasket

   • Function: Used to seal the connection between the bearing housing and other motor components, preventing the leakage of lubricants or other fluids and keeping the motor's internal structure clean and dry. Gaskets also help fine-tune the clearance between parts for improved assembly accuracy.
   • Application Scenarios:
     • Sealing Performance: Given the complex working conditions of EV motors, including high temperatures, vibration, and pressure, metal gaskets must offer excellent sealing to prevent fluid leaks that could affect motor performance.
     • Heat and Corrosion Resistance: Due to potentially high motor temperatures, gasket materials must possess good heat and corrosion resistance, with common materials including stainless steel or other corrosion-resistant alloys.

3. Sleeve

   • Function: Typically used on the motor shaft's exterior to provide support and protection while reducing wear between the shaft and the external environment. EV motor sleeves need high wear resistance and good lubrication properties.
   • Application Scenarios:
     • Wear Resistance and Low Friction: Sleeves frequently contact other components, causing inevitable friction. Therefore, sleeve materials need a low friction coefficient and excellent wear resistance, with common choices being wear-resistant alloys and specialized plastic composites.
     • Lubrication Management: Surface treatments for sleeves (e.g., electroplating or heat treatment) can help reduce friction and facilitate lubricant flow, ensuring smooth and reliable motor operation.

Challenges in EV Motor Systems:

• High Efficiency and Compact Design: EV motors require high efficiency while pursuing compact designs, which demands that components, including bearing housings, gaskets, and sleeves, be as small as possible without compromising performance.
• Lightweight Requirements for EVs: To enhance range, parts need to be lighter. Engineers often use lightweight materials like aluminum, titanium alloys, or carbon fiber composites, reducing weight while maintaining strength and performance.
• Electromagnetic Interference and Heat Management: Since motors generate electromagnetic fields that may affect other electronic systems, especially precision sensors, specialized electromagnetic shielding is needed. Efficient heat management is also crucial to ensure stable motor operation under high load conditions.

Manufacturing Requirements:

• High-Precision Machining: These components usually require precision machining, such as CNC machining, to ensure accuracy and reliability. Bearing housings, gaskets, and sleeves often need extremely tight tolerance control (e.g., 0.005mm) for a secure fit and smooth operation.
• Batch Custom Production: Production often involves small-batch customization, with manufacturers requiring rapid response capabilities to provide flexible production solutions tailored to specific models and designs.

Our Advantages (Product Description):

1. Material Selection:
   We offer material options tailored to the customer's design requirements, as materials must balance strength, wear resistance, corrosion resistance, and weight for EV motor parts.

   • Bearing Housing: We provide custom options such as aluminum alloys, stainless steel, or composites, with precise material recommendations based on high-speed and high-temperature requirements. Aluminum alloys can be used for weight reduction, while stainless steel ensures strength and corrosion resistance.
   • Metal Gasket: We can manufacture gaskets from materials like stainless steel, aluminum alloy, or copper to ensure sealing performance, using high-precision processes such as laser cutting or stamping.
   • Sleeve: For high-wear environments, we produce sleeves from bronze, stainless steel, or high-performance engineering plastics, ensuring wear resistance and self-lubrication for long-term operation.

2. Manufacturing Processes and Machining:
   We have extensive experience in precision machining, including CNC machining, metal stamping, plastic injection molding, and 3D printing, providing comprehensive solutions for critical EV motor components.

   • CNC Precision Machining: Our CNC machining ensures high-precision manufacturing for bearing housings and sleeves, especially for the high tolerance requirements of EV motors (e.g., 0.005mm). Our 5-axis CNC machining capabilities guarantee surface quality and geometric precision, avoiding operational instability due to machining errors.
   • Metal Stamping and Cutting: Metal gaskets often require precision manufacturing through stamping or laser cutting. Our high-precision stamping equipment maintains material properties while achieving efficiency and consistency in mass production. Additionally, we provide solutions for complex-shaped gaskets through laser cutting.
   • Injection Molding and Composite Material Processing: We offer high-precision plastic injection molding services for lightweight sleeves, using suitable engineering plastics such as PTFE or nylon to meet self-lubrication and wear resistance requirements. Our composite material processing capabilities also cater to lightweight design needs in the EV industry.

3. Surface Treatment:
   Surface treatments are crucial for improving wear resistance, corrosion resistance, and appearance quality. We offer various surface treatment options, including:

   • Anodizing: Enhances the wear and corrosion resistance of aluminum alloy bearing housings for complex environments.
   • Plating: Increases the corrosion resistance of metal gaskets and sleeves, suitable for high-temperature and high-humidity conditions, with options such as zinc and nickel plating.
   • Heat Treatment: For steel components, heat treatment enhances hardness and strength, making treated bearing housings and sleeves more durable under high-load conditions.

4. Quality Control and Testing:
   We are ISO 9001:2015 certified, ensuring strict quality standards at every production stage. Quality control is vital for EV components, and our comprehensive inspection processes guarantee high precision, including:

   • Coordinate Measuring Machine (CMM): High-precision equipment for measuring dimensions and tolerances to ensure machining accuracy.
   • Material Testing: Performance tests for heat resistance, wear resistance, and corrosion resistance.
   • Performance Testing: We conduct tests such as heat resistance, wear resistance, and mechanical strength to ensure reliable long-term operation.

5. Fast Delivery and Custom Services:
   With rapid response capabilities, we provide one-stop customized services from prototype design and rapid sampling to mass production. Our fast quoting system and flexible production lines offer tailored solutions for EV manufacturers, ensuring timely delivery for mass production needs.

Trust Longsheng for reliable, high-value, and high-precision manufacturing solutions.

Product Details:

Services Provided:

• CNC Machining (5 Axis, Turning, Milling)
• Precision Stamping and Forming
• Injection Molding for Plastics
• Surface Treatment and Coating Services

Call to Action:
Looking for high-precision custom parts? Contact us today to get a free quote and expert consultation on your CNC machining needs.
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FAQs:

1. What industries do you serve?
We specialize in providing parts for industries such as automotive, aerospace, medical devices, electronics, and more.

2. Can you work with custom designs?
Yes, we accept custom designs and provide expert guidance during the design process to ensure manufacturability.

3. What’s the typical lead time?
Our lead time for samples is 1-3 weeks, and for bulk production, it’s 3-5 weeks.

4. What is your quality control process?
We follow ISO9001:2015 and IATF16949 standards and perform 100% inspections on all parts.