Electric motors are getting smarter, faster, and more efficient, thanks to advancements in laminated rotor and stator stacks. These laminations help reduce energy loss and improve overall performance. With cutting-edge stamping of lamination processes, manufacturers are now achieving greater precision, efficiency, and durability.

New techniques like skewed vs. straight laminations, advanced bonding methods, and insulation processes like epoxy fluidizing are transforming the industry. Let’s dive into these innovations and see how they are shaping the future of electric motors.

Skewed vs. Straight Laminations: Which One Wins?

Laminations in motor cores come in two main designs: straight and skewed. Both have their advantages, but recent advancements have made skewed laminations a game-changer.

Straight Laminations

• Offer simpler manufacturing and lower production costs.
• Are easier to stack and align during assembly.
• Work well for applications where torque ripple is not a major concern.

Skewed Laminations

• Help reduce cogging torque, making motors run smoother and quieter.
• Improve efficiency in high-performance motors, such as those in electric vehicles (EVs) and industrial machinery.
• Enhance power output and motor lifespan by lowering vibration.

With modern stamping of lamination processes, manufacturers can now produce skewed laminations with higher precision. This ensures better alignment, reduced waste, and improved motor efficiency.

The Power of Riveting, Bonding, and Welding in Lamination Stacks

How laminations are held together plays a crucial role in motor performance. Traditionally, manufacturers relied on riveting, but now bonding and welding are becoming more popular.

Riveting

• A tried-and-true method for holding laminations together.
• Provides strong mechanical support, but can create slight gaps between laminations, leading to energy loss.
• Best suited for applications where cost and durability are top priorities.

Bonding

• Uses special adhesives to create a strong, gap-free connection.
• Reduces eddy current losses, improving efficiency.
• Ideal for high-performance motors, like those in aerospace and automotive industries.

Welding

• Fuses laminations together, creating a solid and durable structure.
• Works well for heavy-duty applications where mechanical strength is key.
• Can slightly impact magnetic properties, so it’s not always the best choice for high-efficiency motors.

With advanced automation in bonding and welding, manufacturers are now achieving higher precision and better energy efficiency in motor stacks.

How Epoxy Fluidizing Enhances Motor Performance

Insulation is a critical factor in laminated motor stacks. Without proper insulation, motors can suffer from energy loss, overheating, and even failure. One of the latest breakthroughs in this field is epoxy fluidizing.

What Is Epoxy Fluidizing?

This process involves coating laminated stacks with a thin, even layer of epoxy insulation. The result? A motor that runs cooler, more efficiently, and lasts longer.

Why It’s a Game-Changer

• Reduces energy loss by preventing electrical shorts between laminations.
• Improves heat dissipation, keeping motors from overheating.
• Enhances durability, protecting motors from harsh environments and mechanical stress.

By using epoxy fluidizing, manufacturers ensure that motors maintain peak performance while extending their lifespan.

The Future of Laminated Rotor and Stator Stacks

As electric motors become more advanced, lamination technology must keep up. With the latest innovations in skewed laminations, bonding techniques, and insulation processes, motors are now more powerful, efficient, and reliable than ever.

With ongoing research and improvements in the stamping of lamination process, expect to see even greater advancements in the near future. Whether it’s in EVs, industrial automation, or aerospace, precision-engineered laminations will continue to drive progress.

Looking for the best laminated stacks for your application? Stay ahead of the curve by exploring the latest manufacturing techniques and materials in the industry!