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Electric Motor Components >> BLDC
Stators |
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| Stator
Range:
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Outside
Diameter: 1.5 inch (38mm)
to 5 inch (127mm)
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Inside Diameter: 0.75
inch (19mm) to 3 inch (76mm)
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Size of Lamm Stack: 0.75
inch (19mm) to 4 inch (102mm)
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Size of Magnet Wire: 20
to 38 AWG
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Slot Fill: Up to 60%,
for max efficiency and low temp rise
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Length/ID ration: up
to 6
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Industries
Served:
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Motor manufacturers
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Pump manufacturers
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Commercial
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Generator manufacturers
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Machine manufacturers
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Aerospace
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Contact us if you have
any special or unique configuration. We can
make almost any work.
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The
following information describes our basic manufacturing
steps and processes to produce stators.
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These processes can be customized
as necessary to meet Customer requirements.
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| 1).
Lamm
Stamping |
| Lamm
steel from
quality
steel |
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manufacturers
such as
Nippon |
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Steel (Japan),
Posco
Steel
(Korea), |
| and/or
Bao
Steel
(China).
Core
loss |
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and
stacking
factor are
stable. |
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Typical
grades
include
50A290
(M19) and
50A600
(M45). |
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| 2).
Lamm Stacking |
| All
lamms are
cleaned, aligned, |
| and
TIG welded
to stack assemblies. |
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Custom-made tools and
fixtures |
| provide
alignment
per design |
| specifications.
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| 3).
Insulating
and Curing |
| Insulation
is provided in multiple |
| forms.
Epoxy coatings, including |
| 3M™
Scotchcast™ Powder Epoxy |
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Coatings 260 or 5555 10G, typically
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ranging from 0.012 inches thickness, |
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are applied with a fluidized bed
process and heat cured. |
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| 4).
Coil Winding |
| Magnet
wire of the specified |
| type and size is wound on |
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custom precision chucks to |
| produce coils of the
correct |
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| diameter.
When possible, coils are
wound in series to
eliminate |
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interconnections. In some
special applications
magnet wire is |
| wound
in-place over the
insulated lamination
stack. |
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| 5).
Coil
Inserting |
| Wound coils are inserted into the insulated
slots of the stack. Specialized techniques are |
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used to minimize coil size and thereby attain
lower resistance values, and shorter end turns. |
| When
specified insulation is also placed
between coil phases within the slots and/or
within |
| the
coil
end-turns. |
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| 6).
End-Turn
Forming |
| End-turns
are usually laced to form a neat
package without loose strands of
magnet |
| wire coils.
Using a press and a
specially made forming fixture,
the magnet wire coils |
| are
formed
(compressed) into
their required
dimensions. |
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| 7).
Lead Wire
Soldering
(Optional) |
| Lead wires of
the specified type, size, and
length are connected to
the magnet
wire coils |
| using high temperature solder.
Brazing is also an
available method. Lead
connections are |
| then laced
into the
top end-turns (lead end)
to hold them securely
in place. |
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8).
Lacing
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| Windings are tightly
formed and laced to
act as a single
thermal mass to
reduce hot spots. |
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Tightly packing the
windings also
reduces wire
vibration that cause
acoustical noise and |
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insulation
failure. |
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| 9).
Varnishing
and Baking |
| Varnish operation utilizes customer specified
materials and processes. Facilities, such as |
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Vacuum Pressure Impregnation (VPI), submersion,
trickle down, and heat curing techniques, |
| are
available. Varnishes on
the stator ID can be
cleaned. As an addition
or
alternative to |
| varnishing,
stator assemblies can be
encapsulated with Customer specified
potting materials. |
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| 10).
CNC
Machining |
| Precise
machining of stack surfaces is
available. Stacks can be ground
(outside diameter), |
| honed
(inside
diameter), turned, and milled to
meet to meet the needed dimensions
and |
| features.
Tolerances of ±
0.001 inches (or
closer if required) can be
maintained. |
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| 11).
Physical Inspection
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Inspection
on stack
coating thickness using a coating
thickness gauge.
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Verification
on stack coating adhesion using an impact
test apparatus.
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Dimensional
check on a finished stator using a
caliper, a micro meter, and
an indicator.
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Visual
inspection using a magnifier, or a
projector when it is necessary.
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| 12).
Electrical
Testing/Label Printing
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| Every
unit undergoes a Quality Assurance review.
High
potential voltage, surge, resistance,
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| Back EMF and
other electrical tests are performed as necessary to
assure conformance to
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| Customer specifications.
Test results
are electronically recorded and
stored for future
analysis.
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| If
requested, test results may
accompany each product shipments.
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Test
Fixture
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Test Records
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| Stator
Test System |
| Model
No.: AN8311 |
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