Have you ever wondered how EB549 self-bonding electrical steel is revolutionizing the motor industry? This new lamination technique enhances motor performance and ensures higher efficiency and durability. This comprehensive guide will take you through the essentials of EB549, from the specialized coating and bonding processes to the rigorous testing and inspection protocols.
By the end of this post, you’ll have a thorough understanding of the benefits and applications of EB549 self-bonding electrical steel.
What is EB549 Self-Bonding Electrical Steel?
EB549 self-adhesive coating fluid – the latest product developed by Rembrandt on the basis of EB548 coating fluid. It has the characteristics of thin coating, less glue overflow, fast curing, high lamination coefficient, and can realize online production.
In addition, the bonded cores show optimal thermal conductivity, no hum noise, and do not breathe at temperature changes. Thus avoiding interlaminar corrosion. In addition to the function of bonding, EB549 serves as inter-lamellar epoxy insulating coating.
EB548 applies to wind power generation, rail transit, etc., while EB549 is suitable for electric vehicles, electric aircraft, high-speed motors, and other fields.
Coating and bonding process for electrical steel strip laminations
The self-bonding coating solution is an emerging core stacking method. The self-adhesive coating belongs to the C3 type organic resin coating classified by ASTM A976. Its coating principle and processing method are shown in the figure.
A self-adhesive coating liquid (Stage A: liquid) coating on both sides of the electrical steel base material. The coating liquid thermosetting and baking on the production line to form an incompletely hardened semi-finished product (Stage B: living state). This semi-finished product is processed through production.
The wire coils, slitting, stamping, stacking, and fixing with clamps, and then heated and pressed for curing (Stage C: curing).
The solidified and lamination bonding can avoid the stress and iron loss changes caused by the processing, welding and riveting of electrical steel, improve the overall performance of the motor, and at the same time reduce the vibration and noise generated when the iron core rotates.
Therefore, self-bonding silicon steel is very suitable for high-frequency and high-speed motor products.
Benefits of EB549 Self-Bonding
| Efficiency improvement | 5% |
| NVH（Noise, vibration, sound vibration） | reduce |
| Iron loss reduction | 15% |
| Stacking coefficient | ＞98.5% |
| Parallelism of both ends | ＜0.05 |
| Temperature rise decrease | ○ |
| Light weight and small volume | ○ |
| Exquisite texture and beautiful appearance | ○ |
| Excellent heat dissipation, which can prolong the service life of the motor | ○ |
| There will be no material strain caused by riveting | ○ |
| Reduce the occurrence of eddy current | ○ |
| Reduce capacity loss caused by welding methods | ○ |
| No material stress concentration | ○ |
| Small clearance reduces resonance and improves stator rigidity | ○ |
| Sheet can be used | (T=0.1） |
| Minimize core loss and heat generation | ○ |
| Laminations suitable for thin / hard materials | ○ |
Testing and inspection of EB549 self-bonding electric motor lamination stacks
1. A-state coating liquid detection: viscosity, density, and solid content of the coating liquid.
2. Testing of uncoated electrical steel: testing of magnetic properties and surface roughness of electrical steel.
3. B-state self-adhesive electrical steel testing: adhesion, paint film hardness, coating thickness, insulation testing between silicon steel sheets, and high voltage resistance testing of electrical steel.
4.C state self-bonding motor core detection: bonding strength (T peeling, rolling peeling, shear strength).
5. Self-bonding motor core failure analysis and aging resistance test: high and low temperature oil resistance failure analysis, motor core iron loss detection, etc.
Motorneo Self Adhesive Laminated Core Capabilities
At Motorneo, we have a full-process, multi-functional testing laboratory for self-adhesive coating fluids from state A, state B, and state C.
Motorneo bonding lamination stacks adopt the method of bonding the motor punching pieces together to form the iron core as a fixing method. The motor punching pieces are self-adhesive fixing motor core laminations, which fix on the whole surface of the iron core, and the fixing strength greatly improves.
We offer motor stator and rotor lamination bonding prototyping that does not require mass production, avoiding the situation of insufficient adhesive.
Conclusion
The EB549 self-bonding silicon steel solution not only streamlines manufacturing processes with its rotor and stator bonding capabilities but also fosters durability, precision, and sustainability in the production of electrical steel laminations.
As industries continue to seek higher standards of performance, reliability, and environmental responsibility, EB549 self-bonding silicon steel positions a cornerstone in the evolution of electrical engineering.
FAQS
How is the EB549 coating containered and storaged?
The standard containers are plastic barrels with 200 kg net weight (49 gals) and one-way IBCs (totes) with 1000 kg net weight (245 gals). We grant a minimum shelf life in the original sealed container of 6 months from the date of shipment.
Too high temperatures shorten the shelf life. Warming up over 30°C (86°F), e.g. by direct sunlight, or extreme frost below -30°C (-22°F) have to be avoided.
After partial usage, the original varnish container tightly close with the original closure. It re-uses one month from the date of the first opening.
What is the coating thickness of EB549?
For single-side coating, we recommend a coating thickness of 5..7µm (200..280µin). For double-sided coating 3..5µm (120.. 200µin), depending on the roughness of the sheet metal. With smooth application rollers, the varnish can be applied as delivered.
Thinner coatings can be achieved by dilution with tap water. This is necessary, especially with grooved rollers. In order to avoid a thickening of the varnish in the application unit, we recommend a strip temperature below 50°C (122°F).
How does iron core bonding technology enhance the structural integrity of electrical steel laminations?
Iron core bonding technology employed with EB549 ensures a unified and structurally sound core. This enhances the overall integrity of the electrical steel, contributing to stability and reliability in the final product, such as motors or transformers.