Are you looking to enhance the performance and longevity of your motor by optimizing the adhesive for stator and rotor laminations? Choosing the right adhesive is crucial, as it plays a pivotal role in the overall efficiency and durability of motors.
In this comprehensive guide, we’ll explore the various aspects of selecting the right adhesive for rotor and stator laminations, from understanding adhesive types to factors influencing the choice, bonding techniques, and even eco-friendly options.
What Are Adhesives for Laminations?
Adhesives for laminations, also known as lamination adhesives or bonding adhesives, are specialized materials used to join together stamped laminations in the construction of various devices, such as electric motors, transformers, and generators. These adhesives are designed to securely bond laminations, forming a solid core structure.
Types of Adhesives
Epoxy Adhesives
Epoxy adhesives have exceptional temperature resistance, making them suitable for motors operating in high temperature environments. They also exhibit strong bonding capabilities.
Epoxy resin is the most widely used glue at present, with high strength, strong bonding, and other advantages.
Polyurethane Adhesives
It is mainly used for high-speed rotating motors with good strength and fatigue resistance. But the strength is lower than that of epoxy resin.
Silicone Adhesives
Silicones typically have lower tensile strength and are not as strong as epoxies or polyurethanes, which may be a consideration based on the mechanical loading of the motor.
Acrylic Adhesives
High transparency, strong bonding strength, convenient construction, but poor strength and high-temperature resistance. It is suitable for frequent replacement of rotor lamination.
Cyanoacrylate (Super Glue)
Cyanoacrylate adhesives, commonly known as super glue, provide rapid bonding and are suitable for bonding small components.
Key Properties to Consider For Adhesives Selection
Temperature Resistance
Motors can generate heat during operation, and laminations may be exposed to high temperatures. The adhesive must have the ability to withstand these temperatures without degrading or losing bonding strength.
Electrical Insulation Properties
Electric motors insulate between laminations to prevent short circuits. The adhesive should provide effective insulation to ensure the motor’s electrical performance and safety.
Bond Strength
The adhesive’s ability to create a strong and durable bond between laminations is critical for the structural integrity of the motor core. A weak bond can lead to delamination and motor failure.
Environmental Considerations
Motors can be exposed to various environmental conditions, including moisture, chemicals, and contaminants. The adhesive must be compatible with these conditions to maintain its performance.
Adhesive Type
Different types of adhesives (e.g., epoxy, polyurethane, silicone) offer varying properties and advantages. The adhesive type should align with the motor’s requirements.
Curing Time and Process
The adhesive’s curing time and process can impact production efficiency. Longer curing times may lead to production bottlenecks, while shorter curing times may require rapid assembly.
Select an adhesive with a curing time that aligns with your production needs. Some adhesives offer fast curing options, while others may require longer curing times for maximum bond strength.
Cost-Effectiveness
Assess the adhesive’s cost in relation to its performance and durability. Consider long-term cost savings, including maintenance and replacement costs.
Adhesive Bonding Process
Surface Preparation and Cleaning
Before coating adhesive, ensure that lamination surfaces are clean, free from contaminants, and properly prepared to promote optimal bonding.
Proper Adhesive Application Methods
The adhesive coating method is used to apply the appropriate amount of adhesive on the contact surface of the motor laminate. Requiring the adhesive coating to be uniform, and there should be no leakage and infiltration leakage points.
Curing and Drying Processes
Depending on the type of glue selected, the curing time is also different. In the process of curing, it is necessary to pay attention to the motor stack do not move, so as not to affect the bonding strength of the glue.
Application Areas Of Adhesive Motor Core
Automotive
Punch and adhesive stator and rotor lamination cores are used in electric vehicles (EVs), hybrid vehicles, and in-wheel hubs.
Industrial Machinery
Rotor and stator bonding laminations are integral to various industrial motors, including conveyor systems, pumps, compressors, and manufacturing equipment.
Renewable Energy
Wind turbines and solar tracking systems rely on adhesive motor cores to harness and convert renewable energy efficiently.
Home Appliances
Adhesive motor cores power household appliances such as washing machines, refrigerators, and HVAC systems.
Aerospace
Drone applications use electric motors with adhesive cores.
Medical Devices
Medical equipment, including MRI machines and surgical tools, often incorporate motors.
Consumer Electronics
Electric motors in devices like smartphones, cameras, and drones benefit from adhesive cores.
Our Gluing Technology For Motor Iron Core
From stamping to stacking motor lamination stacks, we innovate step by step. Lamination bonding is a new technology in our company.
Motorneo offers glue dot bonding and self-bonding process to bond stator and rotor laminations. We have multiple various types of high-speed punching machines and multiple disc motor stator punching machines. The largest high-speed punching machine is 350 tons and can produce iron cores with a maximum outer diameter of 1250mm.
We also have three-dimensional coordinate inspection, two-dimensional inspection, core iron loss inspection, stator component voltage withstand inspection, inter-turn inspection, CRH inspection, insulation resistance inspection, and other performance and size inspection capabilities to meet different customer needs.
Conclusion
Selecting the right adhesive for stator and rotor laminations is a critical aspect of motor manufacturing that significantly impacts performance, efficiency, and durability.
As the industry continues to evolve and new technologies emerge, suppliers need to keep up with the latest advances in adhesive technology. This requires significant investment in research and development to develop new formulations and materials to meet the changing needs of customers.
FAQS
Why is adhesive selection important in the manufacturing of electric motors?
Adhesives help increase motor life by preventing fractures in magnets, enable bonding of dissimilar materials, provide impact resistance, vibration-damping characteristics, and enhance overall efficiency and reliability of electric motors. Careful selection of adhesives based on properties like strength, heat resistance, curing times, and compatibility is essential for optimal performance in electric motor assembly.
What is the difference between adhesive and self-adhesive?
Here are the key differences between self-bonding iron cores and gluing iron cores:
Bonding Mechanism:
Self-bonding cores rely on the inherent magnetic attraction or bonding force between laminations to hold them together. No external adhesives are required.
Gluing cores depend on adhesives to create a bond between laminations. These adhesives must be carefully applied and allowed to cure.
Efficiency:
Self-bonding cores are known for their high efficiency because there are no additional materials (adhesives) that can introduce energy losses.
Gluing cores may introduce inefficiencies due to the presence of adhesive materials, which can lead to losses over time.
Manufacturing Process:
The manufacturing process for self-bonding cores involves specialized techniques to ensure laminations bond together inherently.
Gluing cores involve the application of adhesive materials during the stacking process, requiring careful attention to adhesive quality and application.
Durability:
Self-bonding cores often offer enhanced mechanical strength because they rely on the inherent magnetic attraction, reducing the risk of delamination.
Gluing cores may be susceptible to delamination or degradation of adhesive bonds over time.
What are the advantages of adhesive motor core?
The use of adhesive in motor cores, specifically for bonding stator and rotor laminations, offers several advantages that enhance the performance, efficiency, and overall quality of electric motors. Some of the key advantages of using adhesive in motor cores include:
Improved Structural Integrity:
Adhesive bonding creates a strong and durable connection between laminations, preventing delamination or separation during the motor’s operation. This improves the overall structural integrity of the motor.
Enhanced Efficiency:
Proper adhesive application minimizes air gaps between laminations, reducing core losses and improving the motor’s overall efficiency. Lower core losses lead to reduced energy consumption and increased motor efficiency.
Vibration Dampening:
Adhesive bonding can help dampen vibrations within the motor, reducing noise and vibrations that may affect motor performance and longevity.
Higher Torque and Power Density:
The reduced core losses achieved through adhesive bonding can lead to increased torque and power density, allowing motors to deliver more power in a compact design.
Improved Thermal Conductivity:
Adhesives with high-temperature resistance properties help dissipate heat generated during motor operation, contributing to improved thermal performance and preventing overheating.
Reduced Eddy Currents:
Properly bonded laminations can minimize eddy currents within the core, which can lead to energy losses. Reduced eddy currents contribute to higher motor efficiency.
Design Flexibility:
Adhesive bonding allows for more intricate and complex motor core designs, enabling motor manufacturers to optimize core geometries for specific applications.
Corrosion Resistance:
Some adhesives offer corrosion-resistant properties, which can be beneficial in applications exposed to moisture or corrosive environments.
Simplified Assembly:
Adhesive bonding can simplify the electric motor assembly process, as it eliminates the need for mechanical fasteners, such as bolts or rivets. This streamlines production and reduces assembly time.
What bonding technology is commonly used for electric motor laminations in China?
In China, various bonding methods include riveting, cleating, interlocking, glue fastening (conventional bonding), welding processes (TIG welding, MIG welding, laser welding), and emerging technologies like self-bonding.