When the stator core lamination is punched as a whole, a large amount of iron filings are wasted and the material cost is high. The use of slinky laminated cores can reduce waste. In this blog post, we delve into the crucial aspect of how the manufacturing process significantly influences the magnetic properties of slinky stators.
Magnetic Properties in Stators
The stator magnetic characteristics include permeability, saturation, and hysteresis which influence the magnetic flux. Permeability dictates how easily a material can be magnetized, saturation refers to the point at which a material reaches its magnetic limit, and hysteresis accounts for the energy loss during magnetization and demagnetization cycles.
The Slinky Stator Concept
The slinky stator is made of a long electrical steel strip, with slots gradually punching holes in the strip. The steel strip is then rolled into a spiral and welded together. The unwelded lamination resembles a spiral tube.
It is estimated that iron scrap accounts for 30% to 40% of the iron required to stamp the entire stator section into motor laminations. This slinky stator punching process can reduce material waste.
Impact of Manufacturing Processes on Magnetic Properties
The manufacturing of a slinky stator core is the result of a sequence of different processes: straightening, punching, and rolling manufacturing processes lead to a degradation of the magnetic properties. However, it is really difficult from the state of art to classify them a priori from the most influential to the least.
A campaign of magnetic characterization is carried out on FeSi 1.3% specimens extracted after each process on the manufacturing line of a slinky stator. Samples have different shapes, so different characterization methods were used to determine the normal curves and total losses.
Results show that the dispersion in raw material is quite important and depends on the level of induction. Straightening and training processes deteriorate the magnetic material properties and dispersion after both processes is higher than the raw material one.
The effect of rolling and cutting is the most harmful compared to the other manufacturing processes, while the compacting process shows a beneficial effect.
Motorneo Slinky Stator Manufacture Capabilities
Motorneo has multiple automatic lines for “slinky” winding technology, catering to a broad range of specifications from 110 mm to 400 mm outside diameter and electrical steel thicknesses ranging from 1.0 mm down to 0.10 mm.
We employ a punching and rolling process to manufacture helical stators. The materials reduction is 56% compared to the method of punching the entire stator section at one time.
If you have questions related to helical stator lamination cores, please feel free to contact us.
Conclusion
Helical stator stamping requires special manufacturing techniques and production machines. This method can greatly reduce material waste, lower iron loss, and ensure the magnetic saturation and rigidity of the stator. Furthermore, not all geometries can be generated this way.
FAQS
How is a Slinky Stator manufactured?
The manufacturing process involves punching stacked sheet steel bands to create strip laminations with tooth and core portions. These laminations are then spirally wound and integrated, forming the distinctive helical pattern.
What are the key advantages of the Slinky Stator design?
The slinky stator design minimizes material waste through helical stamping, reducing iron waste to only 30 to 40% of the material typically required. This not only enhances efficiency but also contributes to environmental sustainability.
What industries benefit most from Slinky Stator applications?
Slinky stators find applications in a diverse range of industries, including EVs, energy generation, and electromechanical systems.
How does the helical design contribute to the performance of Slinky Stators?
The helical design enhances flexibility and adaptability, allowing slinky stators to excel in applications requiring dynamic movement. This design also contributes to the reduction of material waste during the manufacturing process.