Aluminum Die Casting Rotor Laminations In China
From the meticulous design and simulation of molds to the precision of high-pressure casting systems, we ensure every aluminum die-casting rotor meets the stringent requirements of today’s electric vehicles and industrial applications.
Motorneo’s comprehensive services include motor stator rotor stamping, laser cutting, wire cutting, bonding, stator winding and insulation, and prototyping.
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Capability For Aluminum Die Casting
The aluminum die casting process begins with creating a mold, often made from two hardened tool steel dies. Next, we melt high-quality aluminum alloys or aluminum ingots at controlled temperatures. A hydraulic or die-casting machine injects molten aluminum into the die cavity under high pressure.
Once the aluminum solidifies, our mold is opened, revealing a robust and precisely formed rotor. Then, we process further, such as trimming, deburring, and surface finishing.
We can manufacture various sizes of aluminum rotor cores and a largest outer diameter of up to 1250mm.
Squirrel Cage Rotor Design And Manufacturing
A squirrel cage rotor is a cylindrical arrangement of bars made from a conductive material, typically aluminum or copper, interconnected at each end by conducting rings. It consists of rotor lamination and a squirrel cage and is widely used in industry motors.
Aluminum Squirrel Cage Rotor
We provide two primary manufacturing technologies die-casting and fabricated bars, for producing aluminum squirrel cage rotors.
Die casting involves molten aluminum injected into a mold under high pressure to create the desired shape. In actual production, rotor die casting saves significant production time and cost.
Fabricated bar technology involves assembling individual aluminum bars and end rings to create the rotor structure. The bars are typically stamped(such as compound stamping, rotary notching, and progressive stamping), cut, or otherwise shaped to the desired form before being interconnected. This method is often used for custom or low-volume applications.
die-cast copper rotor
Except for the aluminum die-cast rotor, we deliver die-cast copper rotor services particularly in induction motors.
The die-cast copper rotor process involves high-quality copper alloy melted and injected into precision-engineered molds, resulting in intricate rotor shapes that exhibit exceptional thermal conductivity and electrical performance.
Die-cast copper rotors have increased power density, improved heat dissipation capabilities, and provided a higher power-to-weight ratio advantage. Making them a preferred choice for automotive, industrial machinery, aerospace, and renewable energy.
Benefits of Die Casting Rotor Lamination
The benefits of aluminum die-casting rotors are numerous, making them popular for various industries and applications. Here are some critical advantages of utilizing rotors core in electric motors and generators.
Enhanced Efficiency
Aluminum’s high thermal conductivity allows for better heat dissipation, reducing energy losses due to overheating. This leads to improved motor efficiency and overall performance.
Lightweight Design
Aluminum is significantly lighter than other materials like copper, making aluminum die-casting rotors ideal for applications where weight reduction is essential.
Excellent Conductivity
Aluminum is a good conductor of electricity, ensuring efficient current flow and minimizing energy losses within the rotor.
Reduced Eddy Current
Eddy current losses are minimized due to the lower electrical resistivity of aluminum, resulting in further energy savings.
Cost-Efficiency
Aluminum is more cost-effective than other materials like copper, particularly in high-volume production.
Corrosion Resistance
Aluminum possesses natural corrosion resistance, extending the lifespan of the rotor and requiring less maintenance.
Custom Die Casting Electric Motor Squirrel Cage Rotor
We provide aluminum die-casting rotor laminations and squirrel cage rotor custom service. The application areas include the automotive sector, industrial machinery, wind turbines, hydroelectric generators, aerospace, etc.
Quality Control For Aluminum Rotors
Many factors affect aluminum casting, such as the number of rotor slots, length, and outer diameter. Any tiny mistakes will cause unacceptable defects inside the casting. We employ a rigorous quality control process to validate our products’ integrity, and durability.
1
We utilize weighing as a fundamental inspection method. By precisely measuring the weight of our cast aluminum rotors, we can calculate the actual filling rate of aluminum material. However, the qualified aluminum filling rate does not guarantee the quality of the rotor conductive strip.
2
We employ an X-ray inspection system to meticulously check the porosity of the end rings in our aluminum die-casting rotor laminations. This non-destructive testing can identify even more minor defects and prevent pore defects in the end rings from harming the overall performance of the rotor.
Why Choose Us As Your Aluminum Die Cast Rotor Manufacturer?
What sets us apart is the double cage construction approach. The double cage construction provides better control over magnetic fields, reduces losses, and produces more robust and high-performing electric machines.
Motornoe uses fully automated vertical, and high-pressure horizontal die-casting systems to die-cast rotor cores.
We offer end-to-end solutions, from design and prototyping to production and quality control.
Materials Used In Die Casting Rotor Lamination
Die-casting squirrel cage rotors are typically made from various conductive materials that offer the required electrical conductivity, mechanical strength, and thermal properties. Common materials used in die-casting squirrel cage rotors include aluminum ingot, copper alloys, copper-clad aluminum, and various alloy combinations.
Aluminum Die Casting FAQs
China boasts advanced manufacturing capabilities, skilled labor, and a strong industrial infrastructure, making it a preferred destination for producing high-quality die-casting rotor laminations at competitive costs.
Lead times can vary based on factors like design complexity and order volume. We work closely with you and can help determine a specific lead time for your project.
Aluminum die-cast rotors are widely used in various motors, including induction motors, electric vehicles (EVs), and industrial machinery for their efficiency and durability.
Choosing between aluminum and copper for die casting rotors hinges on balancing cost, weight, and performance. Aluminum offers a lightweight, cost-efficient option with decent thermal management. Copper, despite being more expensive, delivers superior electrical and thermal conductivity, enhancing motor efficiency and performance in high-demand applications.
Choosing the Right China Manufacturer for Squirrel Cage Rotors
If you are looking for a manufacturer that manufactures aluminum squirrel cage rotors? You can discuss it with us. We offer customizable rotor solutions that cater to your specific requirements.
