Axial Flux Stator Lamination Stacks for Electric Motors in China
Motorneo has developed a unique technology to manufacture axial flux motor cores. After years of research and development investment, there are several sets of self-designed and developed disc stator stamping and winding systems, which can meet the needs of mass production.
In addition, we offer customized high-speed and high-efficiency motors. Whether you need a large motor or a small motor, our wide motor solutions can meet you.
Contact us or request a quote for more information about axial flux motor laminations and custom solutions available from Motorneo.
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Customize Axial Flux Stator Lamination Core
Axial Flux motor also called disk motor, is a small weight, compact, high efficiency designed motor. It applies to electrical vehicles, green cars, freeze electric powder generator, and computer disk.
Now due to its advantage of compact size and high power density, it is suitable for more and more fields to replace traditional radixal motors. Motorneo axial flux motor stators for Brushless DC (BLDC) motors, electric vehicles (EVs), electric bikes, electric motorcycles, buses and trucks, electric planes ensuring optimal performance and efficiency.
We offer customized skew slot disc motor stators. The skew slot design enhances motor efficiency and reduces cogging, resulting in smoother operation. Our axial flux motors come with 3M260 coating on the stator, providing an extra layer of protection and durability. This coating not only ensures a longer lifespan for the motor but also enhances its resistance to environmental factors, making it suitable for a wide range of applications.
axial flux motor Stator Lamination Core for EV
Axial flux stator lamination prototype with NO27 silicon steel
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Axial flux electric motor lamination design and manufacture capabilities
Disk motor stator lamination process
The production of axial flux motor stator lamination is essentially different from the traditional stator stacks core.
The lamination direction of the traditional stator using an appropriate lamination stamping process is to stamp or cut a single piece of the same shape, and lamination bonding, interlock, or welding from the axial direction to achieve the parameters and height required to design the product.
The disc stator uses special stamping and rolling integrated equipment, stamps the groove through a dedicated stamping die, and uses a servo synchronous control system to accurately control the stamping frequency and rolling machine speed to ensure consistent alignment of the product diameter from the inner to outer.
Double-sided punching axial flux stator process
However, if the stator has teeth on both planes, then it should How to deal with it? There are two situations:
The two teeth of the stator are in a parallel position: You only need to design a punch when designing the mold, and the two teeth are stamped simultaneously.
The two teeth of the stator are misaligned: Since the distance between the two teeth increases as the rolling radius increases, the traditional mold can no longer meet the requirements.
Dynamic stamping die design is required, that is, the punch is in a moving state, and the stamping time and cycle are precisely controlled by the computer to achieve the required stamping results.
soft magnetic composite Manufacturing Axial motor stator process
We prepare SMC（Sheet Molding Compound）core materials according to customer requirements. The production of soft magnetic composite materials mainly uses metals such as iron and nickel as raw materials. In addition, a certain amount of alloying elements and magnetizing agents need to be added.
Motorneo uses ball milling, and calcination methods to crush the raw materials into fine-grained powder.
Our skilled technicians can according to the requirements of the axial flux stator core, a certain proportion of the sample is taken from the prepared powder sample and mixed evenly according to the ratio requirements for subsequent processing and molding.
The sampled and proportioned powder is uniformly pressed into shapes such as plates or pipes, and molded motor core parts are obtained by shaping.
The pressed molded parts are sintered or heat treated to obtain the final soft magnetic axial flux stator product. In final, surface treatment of the final product is also required so that the final product can meet the usage requirements.
Process of Self-bonding silicon steel to produce stators
The process begins with precision cutting silicon steel strips to the designed width. This step ensures uniformity and accuracy in the stator’s dimensions.
A stamping mold tooling should be designed to stamp the coil shape.
This punching machine has been designed for axial flux stator lamination and it can scroll the stators to the dimensions of Desired ID and OD and ensure each slot has the same position from different layers; normally it can realize +/-0.5mm tolerances for OD and ID Dimension.
To fixate the lamination coil in its designated shape, spot welding is employed on the starting and ending strips.
Stator dimension correction and align laminations for all slots and two plates.
The back plate surface of the stator is subjected to bonding or laser welding.
Depending on the design and application, assembly screw holes may be created at this stage.
To achieve optimal flatness and surface finish, surface grinding may be employed. This step enhances the stator’s overall quality and performance, ensuring that it meets the stringent standards required for electromagnetic applications.
Disc motor stator lamination stacks polygon correction
The production process of disc motor stator is stamping + winding. Through precision system control and synchronization, the number of teeth and lamination thickness are determined by operating system settings.
In fact, when the winding is in progress, the material of the stator teeth has been sheared by stamping, so it cannot be wound in a circle according to the theoretical design, but will become a polygon.
The side length of the polygon is directly related to the size of the stator and the number of teeth. This polygon will be more obvious when the outer diameter of the stator is larger (more than 200mm), or when the number of teeth is less than 24.
Through a unique technical solution, Motorneo can realize polygonal arc correction, so that all stator outer diameters approach the theoretical arc shape.
Axial Flux Stator Winding for Electric Motor
Axial flux stator winding techniques like flat embedded winding and vertical embedded winding optimize the efficiency of electric motors.
In the context of flat embedded winding, conductors are intricately laid out in a flat, planar fashion, offering improved thermal performance and allowing for a more compact motor design. This configuration enhances heat dissipation and facilitates better use of available space.
On the other hand, vertical embedded winding involves strategically placing conductors in a vertical arrangement, further contributing to space optimization.
Both winding methods aim to enhance the magnetic flux distribution within the stator, ultimately leading to increased motor efficiency.
Advantages of Axial Flux Motor Core
Compact Design: Axial flux motors are known for their compact and space-efficient design, making them suitable for applications with limited space requirements.
High Power Density: The axial flux configuration allows for a higher power density, meaning more power can be generated within a smaller and lighter motor.
Improved Heat Dissipation: The design of axial flux motors facilitates better heat dissipation due to the radial path of the flux, preventing overheating and enhancing overall thermal performance.
Efficient Cooling: The open structure of axial flux motors promotes efficient cooling, making them well-suited for applications requiring continuous operation and high-performance demands.
Flexibility in Integration: Their compact design and versatility make axial flux motors suitable for integration into various applications, including electric vehicles, renewable energy systems, and industrial machinery.
Enhanced Torque Density: Axial flux motors often exhibit higher torque density, providing more torque for a given size compared to traditional radial flux motors.
Reduced Copper Losses: The shorter coil lengths in axial flux motors result in reduced copper losses, contributing to higher overall efficiency.
Improved Electromagnetic Efficiency: The axial flux configuration optimizes the magnetic flux path, leading to improved electromagnetic efficiency and better utilization of magnetic materials.
Reduced Inertia: The axial arrangement of the motor components often results in lower inertia, enabling faster response times and improved dynamic performance.
Potential for Higher RPMs: The design of axial flux motors allows for higher rotational speeds, making them suitable for applications where high-speed operation is crucial.
Why Choose us as you axial flux motor manufacturer in China?
Motorneo has focused on the development of disc stator technology for many years. After years of R&D investment, it currently has multiple independently designed and developed disc stator stamping and winding systems, which can meet the daily production capacity demand of 1,000pcs.
Our axial flux stators export all over the world with dimensions from 25mm to 950mm. In addition, we offer an axial flux stator lamination prototype.
As axial flux motor lamination manufacturers, we offer competitive pricing without compromising quality.
axial flux electric Motor Core FAQs
Silicon steel sheets are commonly used as a primary choice for constructing axial flux stator laminations. Additionally, some innovative approaches involve using soft magnet composite materials and amorphous alloys for the motor core to reduce core losses and improve performance.
An axial flux motor differs from a radial flux motor primarily in the direction of the magnetic flux within the motor. In an axial flux motor, the magnetic flux flows parallel to the motor’s axis, moving from one side of the motor to the other.
This is in contrast to a radial flux motor, where the magnetic flux travels radially, moving from the center of the motor to its outer edges.
The axial flux motor design often results in a more compact and lightweight motor with specific advantages in terms of efficiency, power density, and cooling capabilities compared to radial flux motors.
Yes, we often customize the design and dimensions of axial flux motor stator laminations. Which meet the specific requirements of different applications, such as axial flux motors of electric vehicles, industrial machinery, or renewable energy systems.
Our commitment to optimizing axial flux technology ensures seamless integration and enhanced performance across diverse applications.
low cost
Compared with traditional cast iron cores and cold-rolled silicon steel sheet cores, Yokeless axial flux motor stator cores have lower manufacturing costs and can reduce the manufacturing costs of motors.
high efficiency
The magnetic permeability of the SMC core is high, which can improve the efficiency of the motor and reduce the energy consumption and noise of the motor.
Lightweight
The lower density of the SMC core can reduce the weight of the motor and improve the energy efficiency and performance of the car.
high strength
The SMC core has high strength and stiffness, which can improve the durability and reliability of the motor.
In general, axial flux motor stator laminations are designed for reliability and minimal maintenance. However, proper care should be taken to prevent conditions such as excessive heat or moisture that could impact the longevity of the motor.
Get Your Custom Axial Flux Motor Laminations Now!
Revolutionize your electric motor designs with our advanced axial flux motor laminations. Experience enhanced efficiency, compactness, and superior performance.