coreless DC motors

Coreless Motors: A Compressive Guide

Table of Contents

How do you choose the right coreless DC motors for your application? Coreless motors offer numerous advantages, but selecting the best one requires careful consideration. These motors are known for their efficiency, lightweight design, and quick response. To ensure optimal performance, evaluate factors like size, weight, speed, and torque. Additionally, consider efficiency and power consumption, especially for battery-powered devices.

What is a Coreless Motor?

A coreless motor, also known as an ironless electric motor, is a type of DC permanent magnet servo and control motor, often classified as a micro motor. Unlike traditional motors, it features a rotor without an iron core, referred to as a coreless rotor. This design eliminates energy losses due to eddy currents, enhancing efficiency.

Coreless motors are divided into two types: brushed dc motors and brushless dc motors. The rotor of a brushless coreless motor has no iron core, while the stator of a brushless coreless motor has no iron core.

In a coreless DC motor, the laminated iron core is removed. The rotor windings are skewed or arranged in a honeycomb pattern (Faulhaber coil winding), forming a self-supporting hollow cylinder. These coreless motor lamination core windings are typically held together with epoxy.

coreless dc motors structure

Advantages of Coreless DC Motors

Lightweight and Compact

Without the iron core, these motors are lighter and more compact, making them suitable for portable devices and applications where space is limited. Compared with iron core motors of the same power, its weight and volume are reduced by 1/3-1/2.

High Efficiency

Reduced iron losses result in higher efficiency, meaning less energy is wasted as heat. Its maximum efficiency is generally above 70%, and some products can reach more than 90%.

Quick Response

The low inertia of the coreless motor rotor lamination allows for quick acceleration and deceleration, providing quick response times. Some products can reach less than 10 milliseconds.

Low Noise and Vibration

The coreless design minimizes mechanical noise and vibration, making them ideal for applications requiring quiet operation.

Low Starting Voltage and Current

These motors can start at lower voltages and currents, improving energy efficiency and battery life in portable applications.

coreless motor core and housing

Applications of Coreless Motor Lamination

Lightweight and High-Speed Applications

Due to their lightweight design, coreless DC motors excel in high-speed applications such as computer equipment, clocks, medical instruments, and ink-jet printers.

Medical Application

Their high reliability, low noise, and precise control make coreless DC motors popular in medical devices like insulin pumps, x-ray machines, surgical tools, and ventilators.

Aerospace

Coreless motors, with a high power-to-weight ratio, are perfect for drones and model airplanes, operating efficiently on battery power with minimal maintenance.

Single-Phase Induction Motor Applications

Coreless motors are suitable for applications of low-torque, low-speed uses in single-phase induction motors. For higher speed and starting torque needs, a three-phase induction motor is more suitable, used in pumps, fans, and textile machinery.

Robotics

These motors provide quick, precise motions, making them ideal for robotic arms, joints, and wheels, capable of handling continuous start-stop cycles and variable loads without overheating.

robotic coreless motor

Actuators

Coreless DC motors are used in various actuators, including linear, rotary, and pneumatic actuators.

Key Considerations for Choosing a Coreless Motor

When selecting a DC coreless motor, several factors need careful evaluation.

Size and Weight

DC coreless motors are ideal for applications where compact size and minimal weight are crucial.

Speed and Torque

These parameters are critical for assessing performance. The motor’s speed and torque depend on the terminal voltage and the shaft load.

Efficiency and Power Consumption

Efficiency and power usage are influenced by winding type, magnet, and brush materials. Choose a motor with high efficiency and low power consumption to enhance energy savings and battery life.

Noise and Vibration

Performance can be affected by noise from friction and sparks, and vibration from imbalance or misalignment. Motor components like bearings, brushes, and commutators play a key role. Select a motor that operates smoothly with minimal noise and vibration.

Conclusion

Coreless motors offer numerous advantages, making them suitable for a wide range of applications. By understanding their working principles, benefits, and key selection criteria, you can choose the right motor for your needs. Whether it’s for medical devices, robotics, or portable electronics, coreless DC motors provide the performance and efficiency required in modern technological advancements.

Lamnow is a leading motor lamination China manufacturer, we design and manufacture various sizes and types of slotless motors. If you need the coreless motor, contact us today.

coreless motor product

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