produce axial flux stator laminations

How To Produce Axial Flux Stator Laminations?

Axial flux stator laminations play a crucial role in the functioning of axial flux motors, which are gaining popularity for their efficiency and compact design. Understanding how to produce axial flux stator laminations is essential for those involved in motor manufacturing or enthusiasts looking to delve deeper into the technology.

In this guide, we’ll take you through the step-by-step process of producing axial flux stator laminations, from design to quality control.

What Are Axial Flux Stator Core Laminations?

Axial flux stator core laminations are essential components in axial flux motors, a type of electric motor known for its compact design and high efficiency.

In these axial motors, he stator core is designed in a disc or pancake shape. The magnetic flux flows parallel to the motor’s shaft, unlike radial flux motors where it flows radially from the center to the outer edges.

The stator laminations form the core of the motor’s stator, directing the magnetic flux and facilitating energy conversion.  The stator interacts with the rotor to produce mechanical motion.

Typically made from materials like silicon steel, these stator laminates are stacked together and insulated to minimize energy losses and ensure optimal motor performance.  Axial flux stator core laminations play a critical role in the operation and efficiency of axial flux motors.

introduce axial flux stator core laminations

Preparing for Production

Preparing for the produce axial flux stator laminations involves meticulous planning and gathering of materials and equipment essential for the manufacturing process.

Materials Preparation

One of the primary materials used in producing these laminations is silicon steel, chosen for its high magnetic permeability and low eddy current losses. Moreover, utilizing soft magnetic composite materials provides advantages such as improved efficiency and reduced noise.

Equipment Preparation

For equipment preparation, we utilize specialized machinery to cut and shape laminations. This involves punching machines, which precisely cut silicon steel sheets into desired shapes and sizes.

Moreover, we may utilize a powder metal molding press to form laminations from soft magnetic composite materials, offering design and manufacturing flexibility.

Punching Axial Flux Stator Lamination Manufacturing Process

stamping axial flux stator lamination manufacturing process

Cut Silicon Steel:

The first step is to procure or cut silicon steel sheets to the specified width. This material selection is crucial as it must meet design requirements for optimal performance.

Slot Shape Design and Punching:

Develop slot shape punching tooling and utilize specialized punching machines designed for axial flux stator lamination. These machines precisely punch slots with desired dimensions into the silicon steel, establishing the foundation for the stator core’s effectiveness.

Axial Flux Stator Lamination Stamp And Scroll:

Utilize specialized punching machines designed for axial flux stator lamination to scroll the stators to the desired Inside Diameter (ID) and Outside Diameter (OD). This process ensures precise slot alignment across different layers within tight tolerances.

Bonding and Welding:

Once the stator lamination is complete, employ bonding, laser welding, or TIG welding techniques. These methods ensure secure attachment, preventing loosening and enhancing durability.

Manufacture SMC Axial Motor Stator Lamination Process

SMC axial motor stator lamination process

Preparation of SMC Core Materials:

Prepare SMC (Sheet Molding Compound) core materials according to customer requirements, utilizing metals like iron and nickel as raw materials. Technicians add alloying elements and magnetizing agents in specific proportions.

Ball Milling and Calcination:

Employ ball milling and calcination methods to crush the raw materials into fine-grained powder, ensuring uniformity and consistency in particle size.

Mixing and Proportioning:

Skilled technicians carefully take a sample of prepared powder. They mix it evenly according to the required ratio. This ensures precise composition for subsequent processing and molding.

Pressing and Molding:

Uniformly press the sampled and proportioned powder into shapes such as plates or pipes, forming the motor core parts.

Sintering or Heat Treatment:

The pressed molded parts undergo sintering or heat treatment to enhance their magnetic properties and durability. Resulting in the final soft magnetic disk motor stator product.

Surface Treatment:

Apply surface treatment to the final product to meet usage requirements, ensuring optimal performance and longevity.

Conclusion

In conclusion, produce axial flux stator laminations stacks requires careful attention to detail and precision at every step of the manufacturing process.

From selecting the right materials to accurately cutting and shaping the laminations, each stage plays a crucial role in ensuring the efficiency and performance of axial flux motors.

By following the outlined steps and utilizing specialized equipment and techniques, we can create high-quality laminations that meet the stringent requirements of modern motor technology.

With a commitment to quality and innovation, the production of disc motor stator laminations contributes to advancements in energy efficiency and sustainability across various industries.

FAQS

What techniques are used for cutting and shaping axial flux motor stator laminations?

EDM Wire Cutting: Initially introduced for prorotype production, but resulted in imperfect concentricity.

Stamping Mold: Proposed for sample production to achieve better results. A simple stamping mold is used to produce samples efficiently and accurately.

Stamping/Punching Mold: Created for mass production, this mold punches the slots’ shape efficiently. Axial flux stator lamination machine combined with the stamping mold, this machine scrolls the laminations to the desired dimensions.

Whether prototyping or mass production, our technology meets the customize axial flux stator lamination core needs of our customers. Contact us today to discuss your production plan

What are the advantages of using axial flux motor stator cores in motor manufacturing?

High Power Density: Axial flux motors have a higher power density compared to traditional radial flux motors, allowing for more power in a smaller footprint.

Compact Design: The axial configuration of the motor allows for a more compact design, making it suitable for applications where space is limited.

Improved Efficiency: Axial flux stator laminations contribute to increased motor efficiency due to reduced losses and improved magnetic flux paths.

Reduced Weight: Axial flux stator laminations contribute to lighter motor assemblies, resulting in reduced weight and improved portability.

Improved Cooling: The axial arrangement allows for better cooling of the motor components, enhancing thermal management and prolonging motor lifespan.

Higher Torque Density: Axial flux motors offer higher torque density, making them suitable for high-torque applications without increasing size or weight.

Lower Material Costs: The design of axial flux motors often requires fewer materials, leading to reduced manufacturing costs.

Enhanced Control: Axial flux motors offer improved control over torque and speed, making them ideal for precise applications such as robotics and automation.

How do axial flux stator laminations differ from traditional stator laminations?

Unlike traditional stator stacks used in radial flux motors, axial flux stator laminations are arranged in a manner where the magnetic flux travels parallel to the motor’s axis. This design allows for a more compact motor size and increased power density.

In which applications are axial flux stator laminations commonly used?

As a leading motor core lamination manufacturer in China, our custom axial flux stator laminations find applications in various industries. Including automotive, renewable energy, robotics, aerospace, and industrial automation. They are often utilized in electric vehicles (EVs), wind turbines, drones, and high-performance machinery.

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To learn more about our motor lamination manufacturing capabilities for your industry, contact our team today.