motor stator and rotor misalignment

Cause Of Motor Stator And  Rotor Misalignment

Have you ever wondered why precision is paramount in the alignment of motor stators and rotors? Misalignment between these critical components can lead to significant operational issues, reducing efficiency and the lifespan of electric motors. In this blog, we delve into the primary causes of motor stator and rotor misalignment, exploring everything from manufacturing inconsistencies to assembly errors.

The Causes of Misalignment

Variability in Core Expansion

During the manufacturing process, the extent to which the stator core expands can vary greatly. This randomness, coupled with similar issues in the rotor core, leads to misalignment when the entire motor is assembled.

Issues with Cast Aluminum Rotors

For motors with cast aluminum rotors, the special nature of thermal processing can cause the rotor laminations to warp or become concave. This results in significant positioning deviations of the rotor core relative to the stator.

Inaccurate Positioning During Assembly

If the stator core is not correctly positioned during the press-fitting process, or if the rotor shaft positioning steps are inaccurately sized, it can lead to noticeable misalignment between the stator and rotor.

Axial Magnetic Force During Operation

When a motor is running, axial magnetic pull—coupled with suboptimal axial positioning design—can cause cumulative errors in the alignment of the stator and rotor.

Assembly Errors with Bearing Housing

During motor assembly, if the elastic wave washers within the bearing housing are not installed or are installed incorrectly, it can contribute to misalignment.

Incorrect Rotor Orientation

Simply installing the rotor in the wrong direction can cause misalignment.

Rough Machining and Improper Assembly:

Poor machining quality or improper assembly can lead to axial movement of the squirrel cage rotor core, further exacerbating alignment issues.


Understanding the causes of motor stator and rotor misalignment is crucial for maintaining the efficiency and longevity of electric motors. From the intricacies of thermal processing in rotor manufacturing to the precision required in the assembly process, each step plays a pivotal role in ensuring optimal alignment. 

Armed with this knowledge, you can take proactive steps to prevent misalignment, or effectively address it, thus safeguarding the operational integrity of your motors.

If you’re looking to enhance your motor’s performance with custom motor rotor and stator lamination stacks, don’t hesitate to contact us. We’re here to provide you with the best solutions tailored to your needs.

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