In modern motor design, the stator and rotor are core components, and their performance directly affects the efficiency, power density and reliability of the motor. As a key process in the manufacturing process, the bonding of motor core laminations has gradually become the focus of industry attention in recent years. This article will explore in depth the technical principles, advantages and applications of stator and rotor lamination bonding in motor manufacturing.
The stator and rotor cores are usually made of multiple layers of silicon steel sheets (electrical steel) stacked together. The core purpose of this design is to reduce eddy current loss and hysteresis loss. In traditional processes, laminations are fixed by riveting, welding or mechanical clamping, but these methods have some limitations:
may cause local stress concentration, resulting in material deformation or decreased magnetic properties.
high temperature will damage the insulating coating of silicon steel sheets and increase iron loss.
takes up extra space, increases volume and weight.
In contrast, the bonding process achieves seamless bonding between laminations through high-performance adhesives, which not only avoids thermal damage but also simplifies the structural design.
The adhesive fills the tiny gaps between laminations, reducing the air flow path and thus suppressing the generation of eddy currents. At the same time, the uniform bonding layer can effectively reduce vibration noise and improve the smoothness of motor operation.
No rivets or clamping devices are required, the laminations are stacked more tightly, the core volume is reduced, and the power density is significantly improved. This is particularly important for weight-sensitive application scenarios such as new energy vehicle drive motors and drone motors.
After the adhesive is cured, it forms an integral structure that can resist the mechanical stress caused by high-speed rotation or frequent start-stop, thus extending the life of the motor. Especially in high-speed motors (such as turbomachinery with a speed of more than 100,000 rpm), the bonding process can effectively prevent the laminations from loosening.
Avoiding welding fumes and riveting metal waste is in line with the trend of green manufacturing. In addition, the bonding process has a high degree of automation, which can reduce labor costs.
Tesla's drive motor uses bonding lamination technology to achieve higher torque density and heat dissipation efficiency.
ABB's SynRM (synchronous reluctance motor) reduces iron loss through bonding process and improves energy efficiency to IE5 standard.
The variable frequency air conditioner compressor motor significantly reduces operating noise due to bonding technology.
Remove oil and oxides on the surface of silicon steel sheets to improve bonding strength.
Evenly cover the bonding surface by spraying or roller coating, and the thickness of the glue layer needs to be controlled (usually 5-20μm).
Stack the laminations under pressure and use hot pressing or room temperature curing to form a whole.
Remove excess glue, perform insulation testing and dimensional verification.
Develop new adhesives with a temperature resistance of more than 200°C and low viscosity.
Use AI visual systems to monitor the uniformity of the adhesive layer in real time.
Research and development of bio-based adhesives and recyclable laminated materials.
The stator and rotor lamination bonding technology is an important innovation in the field of motor design and manufacturing. It not only solves the pain points of traditional processes, but also provides new possibilities for the efficiency, lightweight and intelligence of motors. With the advancement of materials science and automation technology, this process is expected to achieve breakthroughs in more fields and drive the motor industry towards a higher performance future.
As an stator and rotor lamination bonding stack manufacturer in China, we strictly inspect the raw materials used to make the laminations.
Technicians use measuring tools such as calipers, micrometers, and meters to verify the dimensions of the laminated stack.
Visual inspections are performed to detect any surface defects, scratches, dents, or other imperfections that may affect the performance or appearance of the laminated stack.
Because disc motor lamination stacks are usually made of magnetic materials such as steel, it is critical to test magnetic properties such as permeability, coercivity, and saturation magnetization.
The stator winding is a fundamental component of the electric motor and plays a key role in the conversion of electrical energy into mechanical energy. Essentially, it consists of coils that, when energized, create a rotating magnetic field that drives the motor. The precision and quality of the stator winding directly affects the efficiency, torque, and overall performance of the motor.
We offer a comprehensive range of stator winding services to meet a wide range of motor types and applications. Whether you are looking for a solution for a small project or a large industrial motor, our expertise guarantees optimal performance and lifespan.
Epoxy powder coating technology involves applying a dry powder which then cures under heat to form a solid protective layer. It ensures that the motor core has greater resistance to corrosion, wear and environmental factors. In addition to protection, epoxy powder coating also improves the thermal efficiency of the motor, ensuring optimal heat dissipation during operation.
We have mastered this technology to provide top-notch epoxy powder coating services for motor cores. Our state-of-the-art equipment, combined with the expertise of our team, ensures a perfect application, improving the life and performance of the motor.
Injection molding insulation for motor stators is a specialized process used to create an insulation layer to protect the stator's windings.
This technology involves injecting a thermosetting resin or thermoplastic material into a mold cavity, which is then cured or cooled to form a solid insulation layer.
The injection molding process allows for precise and uniform control of the thickness of the insulation layer, guaranteeing optimal electrical insulation performance. The insulation layer prevents electrical short circuits, reduces energy losses, and improves the overall performance and reliability of the motor stator.
In motor applications in harsh environments, the laminations of the stator core are susceptible to rust. To combat this problem, electrophoretic deposition coating is essential. This process applies a protective layer with a thickness of 0.01mm to 0.025mm to the laminate.
Leverage our expertise in stator corrosion protection to add the best rust protection to your design.
The thickness of motor core lamination steel grades includes 0.05/0.10/0.15/0.20/0.25/0.35/0.5MM and so on. From large steel mills in Japan and China. There are ordinary silicon steel and 0.065 high silicon silicon steel. There are low iron loss and high magnetic permeability silicon steel. The stock grades are rich and everything is available..
In addition to stamping and laser cutting, wire etching, roll forming, powder metallurgy and other processes can also be used. The secondary processes of motor laminations include glue lamination, electrophoresis, insulation coating, winding, annealing, etc.
You can send us your information, such as design drawings, material grades, etc., by email. We can make orders for our motor cores no matter how big or small, even if it is 1 piece.
Our motor laminate lead times vary based on a number of factors, including order size and complexity. Typically, our laminate prototype lead times are 7-20 days. Volume production times for rotor and stator core stacks are 6 to 8 weeks or longer.
Yes, we offer OEM and ODM services. We have extensive experience in understanding motor core development.
The concept of rotor stator bonding means using a roll coat process that applies an insulating adhesive bonding agent to the motor lamination sheets after punching or laser cutting. The laminations are then put into a stacking fixture under pressure and heated a second time to complete the cure cycle. Bonding eliminates the need for a rivet joints or welding of the magnetic cores, which in turn reduces interlaminar loss. The bonded cores show optimal thermal conductivity, no hum noise, and do not breathe at temperature changes.
Absolutely. The glue bonding technology we use is designed to withstand high temperatures. The adhesives we use are heat resistant and maintain bond integrity even in extreme temperature conditions, which makes them ideal for high-performance motor applications.
Glue dot bonding involves applying small dots of glue to the laminates, which are then bonded together under pressure and heat. This method provides a precise and uniform bond, ensuring optimal motor performance.
Self-bonding refers to the integration of the bonding material into the laminate itself, allowing the bonding to occur naturally during the manufacturing process without the need for additional adhesives. This allows for a seamless and long-lasting bond.
Yes, bonded laminations can be used for segmented stators, with precise bonding between the segments to create a unified stator assembly. We have mature experience in this area. Welcome to contact our customer servic.
Looking for a reliable stator and rotor lamination bonding stack Manufacturer from China? Look no further! Contact us today for cutting-edge solutions and quality stator laminations that meet your specifications.
With our expertise, advanced technology, and commitment to excellence, we ensure that every product has the best performance and durability.
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