Motor core Lamination Stacks in China
Motorneo is a motor core lamination stacks manufacturing company that provides our customers with die design, compound stamping, rotary notching, progressive stamping, lamination stacks, die-cast rotors, stator winding, and assembly of finished parts for prototyping and series production.
Contact Us NowStamping Capabilities For motor Lamination
We offer electric motor rotor and stator lamination stamping techniques, including compound stamping, progressive stamping, and rotary notching.
Compound Stamping
The compound stamping technique involves using a compound stamping die, which combines multiple operations into a single stroke.
It begins with a coil of electrical steel fed into a compound die, simultaneously performing stamping operations such as blanking, piercing, and forming rotor lamination and stator lamination cores.
Over half of our compound stamping presses have been matched with automated systems. It enables high-speed production, improved dimensional accuracy, and enhanced repeatability.
Compound stamping is suitable for the medium size motor rotor and stator laminations. It is often used in Industrial Electric Motors, Electric Vehicles (EVs), Hybrid Electric Vehicles (HEVs), Renewable Energy Systems, Elevator Traction motors, etc.
Rotary Notching
Rotary notching is one of our core competencies; It is a cost-effective solution for large diameter electric motor laminations and low-to-medium volume production or large amounts of samples.
This process involves using a rotary notching tool that rotates at high speeds and removes electrical steel to create grooves or slots in the laminations. Our single-solt notching machines employ servo control systems, the notching speeds uo to 1,200 storkes/mins.
The outer diameter of our most extensive punching sheet is as high as 1250mm, currently the giant silicon steel coil’s width.
Progressive Stamping
Progressive stamping technology is our core competitive project, we have multiple 300T high-precision and high-speed progressive stamping lines. And enables the production of motor stator and rotor laminations with tight tolerances and high precision.
This process involves a series of sequential steps, where the silicon steel sheet is progressively fed through the die, carrying out high-speed stamping. It includes cutting, bending, forming, or piercing operations. Small-size but large-volume motor laminations are very suitable to be produced in a progressive die stamping way.
Motorneo progressive stamping motor cores are commonly used in automobiles, home appliances, drones, HVAC systems, power tools, etc.
Rotor&Stator Laminations Stacks Process
Motorneo offers an automation stack and assembles lamination services. Our lamination stacking process includes various methods, including riveting, cleating, laser welding, TIG and MIG welding, glue bonding, and self-bonding.
Design and Manufacture Compound Die
Employs CAD, Wire Electrical Discharge Machining (Wire-EDM), and high-precision grinders to design and craft stamping dies, such as progressive die, compound die, and notching die.
Wire-EDM enables us to create intricate shapes and contours in the die components, ensuring the highest precision and repeatability. Then, our skilled craftsmen utilize grinders to fine-tune the die surfaces, resulting in flawless finishes and optimal tooling performance.
Motorneo mold service department documents all settings and the number of mold strokes daily. To determine the current condition of the mold and estimated remaining life. Customer-owned molds are free of charge for service and repair of molds during their everyday mold life.
Aluminum Die-Casting Rotor Lamination
Aluminum die-casting involves injecting molten aluminum alloy into a precisely designed casting die under high pressure. It allows for the formation of complex rotor shapes with excellent dimensional accuracy.
We can manufacture cast various sizes of aluminum rotors and a largest outer diameter of up to 1250mm and also can deliver aluminum cage rotors that meet the highest industry standards.
For the aluminum die-casting motor rotor quality, we offer to visually inspect porosity, cracks, or unevenness surface defects, such as porosity, cracks, or unevenness.
Motorneo employ non-destructive testing techniques such as x-ray inspection or ultrasonic testing to identify any internal defects or irregularities that may affect the performance of the motor rotor iron core. These tests ensure the integrity and reliability of the die cast rotors.
Stator Assembly Winding In Motor Manufacturing
The stator winding process involves carefully winding the conductive wire onto the stator’s core. We offer two distinct methods for stator winding: automation winding and manual winding.
By automating the winding process, we can significantly increase production throughput, and reduce labor costs. Manual winding involves skilled technicians winding copper coils by hand around the stator core.
For the electric vehicle motor stator, we also offer new automation winding technology such as hair-pin winding, x-pin winding, and i-pin winding.
The winding line way can be customized based on the motor’s requirements, such as the number of poles, winding type (single-phase or three-phase), and desired torque-speed characteristics. The production capacity of the product specification needs to be more consistent. Basic 3-80 sets/day.
Applications Of Electric Motor Core
Motor rotor and stator core lamination find extensive applications across various industries and fields. They are commonly used in automotive applications, powering components such as electric power steering systems, pumps, and hybrid or electric vehicles. Motor stacks are employed in machinery and equipment, including wind/fire power generators, pumps, compressors, conveyor systems, and robotics in the industrial sector.
Quality Control For Motor Stator & Rotor Lamination
Our commitment to excellence is underscored by adherence to international standards such as ISO/FDIS 9001:2008 and ISO/TS 16949 quality management systems. These certifications reflect our dedication to maintaining rigorous processes that consistently meet and exceed industry benchmarks.
1
Using special instruments to inspect the silicon steel sheet used in manufacturing and record the test results of its physical and electromagnetic properties.
2
Coordinate Measuring Machines (CMM) and projector detectors to ensure each component is completed within the required dimensions and tolerances. For medium and large cast aluminum rotors, we use an X-ray system to check the porosity of the end rings.
3
Checking all components have been correctly assembled, there are no flaws or flaws in the stamping or lamination bonding process, and packages.
Why Choose Us As Your Electric Motor Lamination Packs China Manufacturer?
Motorneo has multiple punching press machines, laser cutting machines, wire cutting machines, automation stacking machines, die-casting machines, automation winding machines, injection molding machines, and epoxy powder coating lines.
Our silicon steel detector, CMM inspection, projector detector, and x-ray inspection to strict quality control that ensures that our motor core laminations meet high performance and high permeability, and reduce eddy current losses.
As motor lamination manufacturers, we offer competitive pricing without compromising motor rotor and stator core lamination quality.
Materials Used In Motor Lamination Stacks
Motor laminations are typically made from materials such as silicon steel, nickel alloys, cobalt alloys, thin-gauge electrical steel, amorphous alloys, and soft magnetic composite. Motorneo employs 0.10 to 1 mm thick silicon steel sheets （silicon steel or laminated steel）and 25 μm amorphous metal as the primary material. Motor lamination steel grades used include B20, B35, B50, M15, M19, M22, M27, M36, and M45. Amorphous lamination grades include 2605SA1, 2605HB1M, and 1K101.
Prototype Motor core lamination stacks
We understand the prototype process and provide prototyping lamination stacks services. These prototypes allow engineers and designers to evaluate motor designs’ performance, efficiency, and overall feasibility before committing to full-scale production. We use laser cutting and wire EDM laminations to prototype motor lamination stacks. We work closely with our clients to understand their requirements and provide customized prototype solutions. Our prototyping time is usually 5-15 days.
Motor Core Laminations FAQs
Motor iron core lamination manufacturing includes stamping, laser cutting, wire EDM, compound die manufacturing, cleating, riveting, gluing, and welding. These processes ensure the creation of precise laminations with specific shapes, sizes, and features.
Flat wire motors can pack more stator windings in the same volume, allowing them to output higher power and torque. Additionally, flat wire motors use copper strips instead of copper wires, enabling more copper conductors to be wrapped tightly around the stator teeth, leading to increased efficiency and reduced energy loss.
This technology is crucial for new energy vehicles as it allows for higher power output in the same or smaller volume and weight, ultimately enhancing the performance of electric vehicles.
After stacking the laminations to form the magnetic core, an insulating resin varnish and plastic over-molding can be applied.
Winding Insulate
When winding the wire, use insulating tapes or papers between different layers of winding. Use magnet wire (enamel-coated wire) for the windings. Apply additional insulation( insulating sleeves, resins, or varnishes) where wires exit the slots. After assembly, the entire motor winding can be impregnated with an insulating resin or varnish.
The choice between these techniques depends on factors such as the part’s complexity, production volume, required part accuracy, and specific application requirements.
Compound stamping suits complex parts with multiple forming operations, while progressive stamping is ideal for high-volume production.
Rotary notching is specialized for motor laminations requiring precise notches for winding alignment.
Glue bonding involves applying an adhesive to laminate layers, creating a bond once cured, suitable for permanent structures. Self-bonding, however, uses laminates coated with a bonding agent that activates under heat and pressure during manufacturing, allowing for integral bonding without additional adhesives, and offering ease and efficiency in motor assembly.
Looking for An Industrial Electric Motor Lamination Stacks China Manufacturer?
If you are searching for industrial electric motor lamination manufacturers in China? We can fulfill your requirements with our comprehensive range of services, including die cutting, stamping, stacking, bonding, winding, and aluminum die-casting processes.