Stator bonding lamination technology stands at the forefront of advancements in electrical engineering, changing the construction of stators for electric motors and generators. This new technology plays a pivotal role in enhancing energy efficiency, durability, and overall performance.
In this blog post, we’ll delve into the technology of stator bonding lamination, exploring its manufacturing process, advantages, and other stacking process, and providing valuable insights into its applications across various industries.
What is Stator Bonding Lamination?
All of the motor engineers would like to design the motor with higher efficiency, while some efficiency loss can not be avoided such as the iron loss of the stators. However, when the efficiency target is very strict, a simple improvement in the iron loss decrease would be very helpful for motor efficiency improvement.
Stator bonding eliminates the need for rivet points or welding of the magnetic stator cores, which in turn reduces interlaminar loss. The bonded cores show optimal thermal conductivity, no harmony noise, and do not breathe at temperature changes. Therefore, avoiding interlaminar corrosion.
How Stator Bonding Lamination Works?
Stator Bonding Lamination apply high-temperature Glue/Epoxy Adhesive on the stators to glue the stator sheet together. It does not need any interlock point and welding, so it can lower the iron loss to a maximum level. The typical process of stator bonding is as below:
Coating
Our Lamination Bonding process uses a roll coat process that applies an insulating adhesive bonding agent to the motor lamination sheets.
Curing
The bonding agent is then hot curing. In case of moderate curing temperature a dry, achieve flexible and still reactive coating.
Punching Or EDM wire Cutting Silicon Steel Sheet
At the inception of the stator bonding process, punching and precisely wire-EDM cutting silicon steel sheets to conform to the desired dimensions.
Designing the Lamination Fixture
The design of the composite fixture has a great influence on the efficiency and precision of the stator bonding.
This fixture serves as the framework for assembling the silicon steel sheets, guiding them into the intended configuration.
A well-designed fixture is instrumental in achieving the desired stator height and overall structural integrity.
Bonding with High-Temperature Glue/Epoxy
The heart of the stator bonding process lies in the application of high temperature glue or epoxy to bond the silicon steel sheets together.
This step demands precision and expertise to ensure a secure and durable bond. The use of high-temperature materials is critical to withstand the operational conditions that the stator will encounter during its service life.
Baking
Following the bonding stage, the stator undergoes a baking process to facilitate the hardening of the glue or epoxy.
This step is typically repeated at least two times to guarantee that the bonding material achieves the necessary strength and stability. Baking is a critical phase in solidifying the stator structure, making it resilient to the demands of its intended applications.
Inspection
Quality control in lamination bonding is a critical facet of ensuring the reliability and durability of laminated products.
Thoroughly inspect electrical steel raw materials for composition, thickness, and quality to ensure they meet specifications.
Test adhesives and coatings for viscosity, curing characteristics, and adhesion strength to ensure consistency and performance.
Conduct pull tests, shear tests, or other methods to assess the adhesive’s ability to withstand mechanical stresses and temperature variations.
Use measurement tools like CMM and laser scanners to confirm product dimensions and alignment.
Benefits of Bonded Stator Lamination Technology
Reduced Eddy Current Losses
Bonding the laminations together effectively reduces the gaps between them, which minimizes eddy current losses.
Improved Thermal Management
The uniform and secure bonding of stator laminations enhances the thermal conductivity within the stator core. This allows for better heat dissipation, crucial in high-performance applications.
Enhanced Mechanical Strength and Rigidity
Bonded laminations provide greater structural integrity to the stator. The bonding materials used often contribute to a more rigid core that can withstand higher mechanical stresses and vibrations during operation, reducing the likelihood of structural failure.
Noise Reduction
The bonding of stator laminations can significantly reduce acoustic noise and vibrations. Since there are no loose parts or significant gaps within the stator core, the minimized operational noise.
Other lamination technology for stator stack laminations
Interlock lamination stacks
The interlocking iron core uses automatic stacking riveting technology on the progressive die. The formation process of the interlocking iron core is to make the convex part of the stacking riveting point of the previous piece correctly align with the stacking riveting point of the lower piece at the blanking station.
The dot concave holes are overlapped together. When the upper piece is subjected to the pressure of the blanking stamp, the lower piece uses the reaction force generated by the friction between its shape and the wall of the die to cause the two pieces to overlap.
Through progressive punching by a high-speed automatic stamping machine, forming a neat iron core with a certain stack thickness.
Welding electric motor laminations
Welding joining the laser/stamped single-piece silicon steel sheets together using welding seam techniques. This technology normally used for prototype sample customization and special application where has large torque.
Our main welding processes include TIG+MIG welding, laser welding, resistance welding, etc., which have the advantages of mature technology, low cost, low requirements for lamination, and low requirements for equipment.
Blot Motor Iron Core
Bolting is a common method for securing stator laminations, particularly in instances where the outer diameter of the stator is larger.
This approach involves the use of bolts strategically placed around the periphery of the stator to fasten the laminations together securely.
The choice to utilize bolts is often influenced by the need for additional structural integrity in larger stator assemblies, where the forces and stresses are more substantial.
Cleating stator laminations
Buckle stacking is a technique suitable for the assembly of stator laminations, contributing to the efficient construction of electric motors and generators. This method involves the strategic arrangement of laminations, utilizing either straight or skew buckles.
Straight buckles use a linear fashion alignment, offering a straightforward stacking configuration. While skew buckles introduce an angular element, enhancing the overall stability and performance of the stator core.
Buckle stacking plays a critical role in optimizing the magnetic circuit within the stator, ensuring precise alignment of laminations and minimizing energy losses.
Motorneo stator and rotor lamination bonding and manufacturing capabilities
Motorneo is capable of full-process stator and rotor sample production and mass production from raw material procurement, wire cutting, stamping, gluing, or welding lamination.
We have multiple various types of high-speed punching machines and multiple disc motor stator punching machines. The largest high-speed punching machine is 300 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.
More details about stator bonding technology, please feel free to share with us your drawing and technical requirement.
Conclusion
From the initial steps of coating and curing to the intricate procedures of bonding and baking, this technology enhances motor efficiency, durability, and noise reduction. We also compared it with alternative methods such as interlocking, welding, and cleating, underscoring the unique advantages of bonding.
As we peer into the future of electric motors, the stator bonding lamination technology will be a driving force, ushering in an era of heightened performance and longevity in electrical machinery.
FAQS
Are there specific industries where stator bonding lamination is more commonly used?
Stator Bonding Lamination finds widespread application in industries such as automotive, industrial manufacturing, and renewable energy. Its adaptability makes it suitable for various applications where efficient and durable electric motors are essential.
What types of bonding materials are commonly used in stator bonding lamination?
In stator bonding lamination, various bonding varish are used to securely join the laminations and form a robust stator core. The choice of bonding material is crucial, as it affects the performance, durability, and thermal characteristics of the stator.
Commonly used bonding materials include EB549 self-bonding coating, Magna-Tac E645, Magna-Tac F310, 3M™ Scotch-Weld™ 2290, Z, Backlack, Suralac 9000, etc.
Can stator bonding lamination be reversed or undone once applied?
Once the lamination process is complete, it is challenging to reverse. Thorough planning is crucial before initiation, considering the irreversibility of the bonding process.
