Working with segmented stators is an important part of the motor design. In a motor, the stator is composed of several core sheets, and a “segmented” stator divides the core sheets into multiple sections. In this blog post, we’ll delve into the intricacies of working with segmented stator lamination stacks, exploring their fundamental principles, benefits, and applications.
What is Segment Motor Lamination?
In traditional motor designs, the stator laminations are continuous and cover the entire circumference of the stator core. However, in segmented motor laminations, the continuous lamination is replaced by segmented or individually insulated laminations that cover only a portion of the stator core.
Segment laminations, also known as T-segment laminations, is the iron core is divided into several parts. Each iron core’s inner measuring arc edge is concave to form a plurality of tooth slots. Then, the multiple rings punched are superimposed segmented stator winding together, and the joints on the adjacent rings are staggered. Achieve a complete motor core.
Manufacturing Process of Segmented Stator Lamination Stacks
Segmented stator laminations typically utilize high-speed stamping machinery and mold capable of producing each segment motor core with tight tolerances efficiently.
The interlocking process is carried out in a progressive stamping die, and the interlocking points of each motor stack are interlocked layer by layer to form a completed motor core segmented. Segmented stator also employs the self-bonding process to bond laminations.
The segmented iron core through a dovetail groove or welding process to form a complete circular motor laminate pack. Segmented stator lamination cores are common with 12 slots and 10 poles or 12 slots and 14 poles. It is suitable for the outer diameter of relatively large lamination iron core products to save material use.
Benefits of Working with Segmented Stator Lamination Stacks
Increased Efficiency
The segmented design minimizes eddy current losses and core losses, resulting in a more efficient energy conversion process.
Enhanced Heat Dissipation
With increased surface area and gaps between segments, heat can escape more easily. Preventing the motor from overheating and improving its durability and performance under high-load conditions.
Reduced Magnetic Losses
The innovative design reduces motor stator iron core losses, leading to higher energy efficiency.
Quieter Operation
The reduction in magnetic noise, a byproduct of the segmented design, contributes to quieter motor operation.
Improved Power Factor
Segmented stator lamination stacks can lead to an improved power factor, a measure of how effectively electrical power converts. This can have positive implications for the overall efficiency of the electrical system.
Reduced Material Wastage
The process of creating segmented laminations typically involves precision cutting techniques such as laser cutting, which can be highly efficient in terms of material use.
Lower Manufacturing Costs at High Volumes
The ability to use automated processes for cutting and assembly helps drive down costs in large-scale production settings.
Applications of Segmented Stator
Segmented stator lamination stacks find diverse applications across various industries, showcasing their versatility and efficiency in different contexts:
Electric Vehicle Motors
Segmented stators can improve EV motor efficiency and enhance thermal management, thereby extending the vehicle’s range.
Industrial Motors
Segmented stators are used in industrial motors that require high precision, such as those used in robotic arms, and conveyors.
Renewable Energy Systems
Segmented stacks play a significant role in renewable energy systems, such as wind turbines and solar power generators. Their efficiency and ability to handle variable loads make them well-suited for these applications.
Appliances and Consumer Electronics
In household appliances and consumer electronics, where compact and energy-efficient motors are essential, segmented stator lamination stacks find applications. This includes appliances like refrigerators, washing machines, and power tools.
Aerospace
Electric motors with segmented stators are used in various aerospace applications, including actuators, pumps, and fans.
Marine Propulsion
Electric and hybrid marine propulsion systems use segmented stator motors to maximize efficiency and minimize emissions.
Motorneo Segmented Stator Stacks Manufacture Capabilities
Motorneo produces electrical laminations and lamination segments ranging from 20 mm to 1250 mm in diameter.
Having multiple 25T-300T punching machines to mass production motor lamination stacks.
For lamination prototyping, we offer laser cutting and wire cutting(low-speed, medium-speed, and high-speed) to rapidly cut electrical steel lamination.
Segmented stator laminations use 0.1mm – 1mm silicon steel and 25μm amorphous materials.
Whether mass production or prototyping, Motorneo’s manufacturing capabilities ensure the production of segmented stator stacks that meet the highest standards of performance and reliability.
Conclusion
Segmented stator lamination stacks offer enhanced efficiency, superior thermal management, and greater flexibility across a range of applications. From their precise manufacturing processes to their broad implementation in industries such as electric vehicles, aerospace, and renewable energy, these segmented stator components are crucial for developing more reliable and efficient systems.
FAQS
What is a segmented stator lamination in the context of an induction motor?
A segmented stator lamination in an induction motor refers to the use of individually insulated laminations instead of continuous lamination around the stator core. This design enhances the efficiency and performance of the motor.
How are the segmented cores stacking assembly together?
For segmented silicon steel lamination bonding and stacking, we utilize both a self-bonding process and an interlocking method to assemble silicon steel lamination segments.
Our self-bonding process uses silicon steel sheets coated with adhesive varnish. At certain temperatures and pressures, the silicon steel laminations will self-bond without additional adhesives.
The interlocking process is carried out in a progressive stamping die, and the interlocking points of each motor stack are interlocked layer by layer to form a completed motor core segment.
The segmented iron core is spliced together by a dovetail groove or welding process to form a complete circular motor laminate pack.