BLDC Motor Lamination Stacks Manufacturer In China
Motorneo is a leading manufacturer based in China, we specialize in producing top-notch motor laminations tailored specifically for BLDC motors. Whether you’re in the automotive, robotics, or renewable energy sectors, our lamination stacks ensure optimal performance, efficiency, and durability for your BLDC motor applications.
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Customized Stator And Rotor Lamination For Brushless DC Motor
Motorneo specialize in crafting customized rotor and stator laminations for Brushless DC (BLDC) motors, offering tailored solutions to meet diverse application needs.
Brushless DC motors are renowned for their efficiency, reliability, and precise control. The electrical steel laminations of BLDC motors find application in a wide range of industries and technologies.
In automotive, our BLDC motor rotor and stator apply for seat motors, wiper motors, power steering motors, oil pump motors, fan motors, etc. Additionally, it is widely used in electric vehicles, electric bicycles, electric motorcycles, and electric scooters.
In robotics and automation, these brushless motor stator laminations are suitable for robotic arms, CNC machines, 3D printers, and other automated systems.
Another significant application of BLDC motor laminations is in renewable energy systems such as wind turbines and solar tracking systems.
Brushless DC motors are utilized in HVAC systems, household appliances, aerospace drones, medical devices, and many other fields where efficient and reliable motor control is essential.
Strip BLDC stator laminations
BLDC motor lamination core for drone motor
t-type amorphous BLDC motor iron core
segmented BLDC motor stator Laminations
BLDC stator laminations For New energy vehicles motor
bLDC motor lamination stack For Wind Turbines
Brushless DC Motor Lamination Prototyping
Motorneo utilizes advanced techniques such as laser cutting and wire EDM (Electrical Discharge Machining), we offer efficient and accurate fabrication of Brushless DC motor lamination prototypes.
Laser cutting ensures intricate designs are replicated with precision, while wire EDM enables the production of complex shapes with minimal material wastage.
Our streamlined process allows for quick turnaround times, with lamination prototype lead times ranging from 7 to 15 days. This swift production timeline enables our clients to accelerate their product development processes and swiftly iterate on design concepts.
Tooling Design And Manufacture For Brushless Motor
Motorneo offers services for designing and building custom stamping dies tailored to customer specific needs for consistent and high-quality lamination production.
Engineers use CAD software to aid in modeling and simulating the tooling design to refine accuracy and efficiency. The manufacturing phase involves CNC machining or EDM processes to craft the tooling components with exacting precision.
Lamination Stamping For BLDC Motor
We offer high-speed stamping, compound stamping, single-slot punching advanced stamping techniques tailored to meet diverse manufacturing needs.
Progressive stamping enables rapid production of intricate laminations with precision and consistency, ideal for small laminations and high-volume manufacturing.
Compound stamping allows for the creation of stator rotor laminations of good flatness and verticality. It is suitable for medium and large laminations.
The rotary notching process employs servo control systems to ensure precise and uniform notches. It is suitable for large laminations and prototypes.
Lamination Bonding And Stacking For Brushless Motor
BLDC motor lamination bonding and stacking involve a single stator rotor lamination stacked together to form a complete motor core.
Glue bonding uses the adhesive applied to the lamination sheets, which are then stacked to the desired height for assembly. Self-bonding laminations eliminate the need for additional adhesives, streamlining the manufacturing process while ensuring structural integrity.
The interlocking motor lamination process involves the interlocked points of each single lamination being pressed down into the one underneath it in the progressive die.
For more robust bonding, we employ laser welding and TIG welding technique ensuring a strong and durable bond between laminations. We also offer riveting and cleating processes for securing laminations, providing mechanical reinforcement in high-stress areas.
Electrostatic Epoxy Insulation Coating BLDC Motor Stacks
Motorneo offers an electrostatic epoxy insulation coating process for BLDC motor stacks. We have multiple automation epoxy insulation lines. With coating thickness ranging from 0.15mm to 0.6mm.
We have multiple automation epoxy insulation lines. With coating thickness ranging from 0.15mm to 0.6mm, we offer customizable solutions tailored to meet specific application requirements.
Utilizing high-quality epoxy resin materials such as 3M860, 3M266, 3M260, 3M555, and 3M5230N, we guarantee exceptional performance and durability.
With a temperature resistance of up to 180℃, our coatings maintain integrity under high operating temperatures, enhancing the longevity and efficiency of BLDC motors.
Injection Molding For BLDC Motor Stator Core Lamination
This method involves injecting molten materials, typically thermoplastics, into a precision-designed mold cavity under high pressure. The mold is intricately crafted to form the desired shape of the stator core lamination.
We offer injection molding materials including PA, PPS, PET fiberglass high loaded, and BMC. In our factory, we have multiple plastics over molding equipment.
Stator plastic over-molding offers numerous advantages, including rapid production cycles, cost-effectiveness, and exceptional accuracy.
BLDC Motor Stator Winding
This motor stator winding process involves winding insulated copper wire coils around the stator core to create electromagnetic fields that propel rotor motion.
Each winding must be precisely placed and secured to ensure optimal electrical conductivity and mechanical stability.
Our advanced winding techniques, such as automated winding machines, are employed to achieve consistent winding patterns and tension control.
Advantages Of Brushless Motor Core
Efficiency: Brushless motor cores typically have lower electrical losses, resulting in higher efficiency compared to brushed motors.
Improved Heat Dissipation: Brushless motor cores often feature better heat dissipation properties, allowing for prolonged operation at higher temperatures without compromising performance.
Maintenance-free: Brushless motor cores require minimal maintenance due to the absence of brushes, reducing downtime and associated costs.
Precise Control: Brushless motors provide precise speed and torque control, offering smoother operation and improved performance.
Higher Power-to-Weight Ratio: Brushless motors typically offer a higher power-to-weight ratio, making them suitable for applications where weight is a concern.
Reduced Electromagnetic Interference (EMI): Brushless motor cores generate less electromagnetic interference compared to brushed motors, making them suitable for applications where EMI is a concern.
Quieter Operation: The absence of brushes results in quieter operation, making BLDC motors ideal for noise-sensitive applications.
Reliability: Elimination of brushes reduces wear and tear, enhancing the longevity and reliability of the motor.
Quality Control For BLDC Motor Core
1
CMM is used to precisely measure the dimensional accuracy of critical features on the motor core, ensuring adherence to design specifications.
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2D imagers are utilized to inspect the surface quality and detect any defects such as scratches, dents, or imperfections that may affect the performance of the motor core.
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X-ray inspection is utilized to inspect internal features of the motor core, such as winding integrity and alignment, without damaging the component.
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Visually inspect the motor core for defects, anomalies, or irregularities in the winding pattern or alignment.
Why Choose Us As Your BLDC Motor Iron Core Manufacturer?
Our production equipment includes 25T-300T stamping machines, laser cutting machines, low-speed EDM wire machines, medium-speed EDM wire machines, high-speed EDM wire machines, automatic stacking, welding machines, injection molding machines, epoxy power machines, and automatic winding machines.
We employ progressive stamping, compound stamping, rotary notching, laser cutting, and wire cutting processes to manufacture stator and rotor laminations.
Motorneo leverages bonding and stacking technologies, including laser welding, riveting, cleating, TIG+MIG welding, self-bonding, and gluing to assemble iron cores.
The motor rotor and stator lamination samples’ lead time is 5-15 days.
BLDC lamination stacks FAQs
Laminations are crucial in brushless motors because they provide a path for the magnetic flux generated by the stator windings. By laminating the core, eddy current losses are minimized, improving motor efficiency and reducing heat generation.
Silicon steel (also known as electrical steel) and iron are the most commonly used materials for BLDC motor laminations due to their magnetic properties and low electrical conductivity, which helps minimize eddy current losses.
We also offer amorphous alloy materials, nickel alloys, and cobalt alloys.
The stacking factor refers to the ratio of the actual cross-sectional area of the core to the total cross-sectional area available for the core. A higher stacking factor indicates better space utilization and can contribute to higher motor efficiency.
Precise alignment during lamination stacking is achieved through automated stacking machines or fixtures that hold the laminations in place during assembly. Additionally, precision cutting techniques and quality control measures ensure uniformity and alignment accuracy.
Selecting brushless motor laminations for multi-rotor drones, like those crafted from silicon steel, ensures optimal efficiency and performance. These laminations minimize energy loss from eddy currents, optimizing magnetic flux for smoother operation and longer flight times. Quality materials are essential for maximizing power output while minimizing heat generation and energy consumption.
High-Quality BLDC Motors Laminations!
Upgrade your BLDC (Brushless Direct Current) motors to new heights of performance and reliability with our advanced laminations. Let’s start your project.
