Permanent Magnet Brushless DC Motor and Mechanical Structure Design for the Electric Impact Wrench System

This paper presents an analytical method to design an interior permanent magnet brushless DC electric motor (IPMBLDC motor) for a kind of electric impact wrench used for loading and unloading car bolts. It takes into account magnet assembly gap, rotor saturation webs, and bridges. Assumed flux leakage coefficient and selected working point of a permanent magnet were used in the initial design. An advanced equivalent magnetic circuit was developed to verify the total flux leakage and the quiescent operating point based on initial design parameters. Key design method points are considered and analyzed. Thermal analysis is given to simulate the temperature rise of all parts of the motor. The new impact wrench mechanical structure is designed, and its working principle analyzed. An electromagnetic field analysis based on MATLAB and the MAXWELL 2D finite element method (FEM) were used in the design to verify the equivalent magnetic circuit and optimize the IPMBLDC motor parameters. Experimental results are obtained to verify the design. The electrical and mechanical designs are combined and an analytical IPMBLDC motor design method is provided. We also show an innovative and reasonable mechanical dynamical calculation method for the impact wrench system, which can be used in whole system design of other functional electric tools.