advantages of bonding stator rotor lamination in new energy vehicle motor

Advantages Of Self Bonding Stator And Rotor Laminations In New Energy Vehicle Motors

In the dynamic realm of electric mobility, the method of glue bonding has emerged as a revolutionary force, reshaping the landscape of NEV motor construction. This blog unravels the multifaceted benefits that self bonding motor laminations in NEVs, from enhanced structural integrity to optimal thermal performance.

Join us on this journey as we delve into the pivotal role that glue bonding plays in advancing the efficiency, reliability, and sustainability of new energy vehicles.

Understanding Rotor And Stator Laminations

At the heart of electric motors lie the rotor and stator core, intricately designed components crucial for optimal functionality. Traditionally, these laminates were joined using methods like welding and riveting. However, the paradigm has shifted with the adoption of self-adhesive technology. 

self bonding motor lamination in NEVs

Because the new energy vehicle motor is driven by a battery, increasing its driving range is a core factor related to user use and improving product competitiveness.

According to the principle of motor design, the eddy current loss of the motor is proportional to the square of its operating frequency. When the motor is running at high speed, how to reduce the eddy current loss is the key factor to improve the motor performance efficiency.

Through the self-bonding motor stator and rotor stacks method, we achieve a seamless integration of laminations, enhancing the overall structural integrity and magnetic properties of the motor.

The Rise of New Energy Vehicles

The increasing global shift towards sustainable transportation has catapulted the prominence of new energy vehicles. As electric cars, buses, and bikes become commonplace, the demand for high-performance electric motors escalates.

Stator and rotor laminations, traditionally viewed as mere components, are now recognized as critical elements influencing the efficiency and sustainability of NEVs.

Motor Lamination Bonding Technique

In the realm of electric motor manufacturing, the process of bonding motor laminations is pivotal to ensuring structural integrity and performance. The two prominent bonding technologies employed – are glue dot bonding and full-surface bonding.

Glue Dot Bonding Process

motor laminations glue bonding technique

Glue dot bonding involves applying adhesive in precise, strategically placed dots across the surface of the laminations. This method ensures targeted bonding points, allowing for controlled adhesive application. The dots serve as anchor points, securing laminations together while leaving designated areas for heat dissipation.

Full-Surface Bonding Process

In the pursuit of enhancing electric motor efficiency, self bonding technology has emerged as a groundbreaking solution. Due to eliminating the need for external adhesives. This innovative approach revolutionizes the construction of motor components, particularly stator and rotor laminations.

Backlack Self-bonding involves the integration of adhesion properties directly into the material composition of stator and rotor laminations.

Rather than relying on external adhesives, the laminations themselves possess bonding capabilities when exposed to specific conditions, such as heat or pressure. This results in a full-face bond without the need for additional bonding agents.

Advantages of Self Bonding Electric Motor Laminations In NEVs

advantages of bonding electric motor laminations in NEVs

Streamlined Manufacturing Process:

Self-bonding motor laminations in NEVs eliminate the need for additional adhesives or bonding agents, streamlining the manufacturing process. This results in increased efficiency, reduced production time and ultimately lowers manufacturing costs.

Enhanced Structural Integrity:

The self-bonding process creates a robust and integral bond between laminations, significantly enhancing the structural integrity of stators and rotors.

Through relevant tests, a self-bonding lamination coefficient of 94%-95% can be achieved (based on a 0.2mm silicon steel sheet). A glue dot bonding lamination coefficient of 97% can be achieved (based on a 0.2mm silicon steel sheet).

Reduced Weight and Material Usage:

Self-bonding allows for the use of thinner laminations without compromising structural stability. This reduction in material thickness contributes to the lighter stator and rotor assemblies, addressing the ever-present need for weight reduction in electric vehicles.

Improved Heat Dissipation:

Efficient heat dissipation is critical for the optimal performance of electric motors. Lamination stacks with the narrowest manufacturing tolerances improve the dissipation of heat through improved transfer of heat between the laminations and the housing.

Reduces Eddy’s Current Loss:

The glue bonding stator rotor reduces eddy current loss caused by the interlayer conductivity to zero, so the glue bonding stator rotor core technology has a natural advantage in high-end efficient, and high-speed motors.

Reduce Vibration And Noise:

Using glue to fix the layers significantly improves the vibration and noise of the motor at high speeds compared to the welding process.

Design Flexibility:

Self-bonding technology provides greater design flexibility, enabling the creation of intricate and space-efficient stator and rotor configurations. This flexibility is particularly advantageous in the evolving landscape of compact and high-powered electric motors.

Cost Efficiency:

By eliminating the need for external bonding agents and simplifying the manufacturing process, self-bonding results in cost efficiencies. This makes electric motors more economically viable and supports the broader adoption of electric vehicles.

Enhanced Electrical Performance:

Self-bonding minimizes the gaps between laminations, improving the magnetic field within the motor. Imported adhesive with UL certification that has passed 200 degrees high temperature is used to ensure the safety of its electrical machine performance.

Lamnow Electrical Steel Lamination Bonding Capabilities

lamination stacks bonding and stacking

With years of expertise, Lamnow is a trusted leader in motor core lamination stacking, specializing in stator rotor adhesive solutions.

Our comprehensive capabilities span various aspects, including lamination stamping, lamination stacking, coating insulation, lamination prototype, and thorough testing.

Lamnow offers a diverse range of bonding solutions, encompassing both manual adhesive bonding and innovative self-bonding techniques. Clients have the flexibility to choose the stacking approach that best suits their project requirements. 

Our commitment to tailored motor lamination stacks solutions ensures that every client can make informed decisions based on their unique needs. Elevate your manufacturing processes with Lamnow’s cutting-edge bonding capabilities.

Conclusion

In conclusion, the advantages of self-bonding technology for stator and rotor lamination stacks in new energy vehicle motors and hub motors are undeniable. This innovative approach not only enhances structural integrity but also streamlines manufacturing processes, reducing production time and costs. 

The resulting motors are not only more efficient but also lighter, contributing to the overall weight reduction imperative in the electric vehicle industry. With improved heat dissipation, design flexibility, and a focus on environmental sustainability, self-bonding emerges as a cornerstone technology, shaping the future of electric mobility.

FAQS

Is self-bonding technology limited to specific types of laminations?

No, self-bonding technology is versatile and can be applied to various types of laminations commonly used in the construction of stators and rotors for new energy vehicle motors, UAV motors, rail transportation Linear motors, industrial motors, home appliance motors, and more.

What are the commonly used bonding materials for motor lamination?

Several bonding materials are commonly used for motor rotor and stator lamination stacks manufacturing. The choice of bonding material depends on factors such as the type of motor, performance requirements, and the intended application. 

Here are some commonly used bonding materials: EB540, EB546, EB548, EB549, Magna-Tac E645, Magna-Tac E8899, 3M™ Scotch-Weld™ 2290, Suralac 9000, and more.

Is self-bonding technology cost-effective compared to traditional bonding methods?

While initial costs may vary, self-bonding can be cost-effective in the long run. The streamlined manufacturing process, reduced material usage, and potential weight savings contribute to overall cost efficiency.

In addition to bonding, what are the methods of motor stacking?

In addition to adhesive bonding, several methods are employed for stacking laminations in electric motors. These methods play a crucial role in determining the structural integrity, performance, and efficiency of the motor.

There are some common methods of motor stacking: interlocking, laser welding, TIG welding, MIG welding, riveting, cleating, blots, etc.

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