The rotor and stator revolution
They form the heart of any electric engine – stator and rotor.
An electric current causes a core (rotor) to rotate within the magnetic field of a static electromagnet (stator). To minimise unwanted and uncontrolled electromagnetic fields, stators and rotors are compiled from layers of thin electric steel (laminations) that are isolated from each other.
Traditionally, the laminations were punched, then stacked and fixated, using punch-packed stacking, welding and clamping. However, this method will locally destroy or bridge the insulation layer between the laminations.
As a result, the stacks carry compromised electromagnetic properties that cannot be measured accurately. From an efficiency point of view, the manufacturing of punch-packed stacked stacks is comparable to the compacore® method. Stack bonding has so far only been relevant for the manufacturing of prototypes and pre-production runs as it required a multi-stage manufacturing process. While there is a spot bonding method producing finished stacks, the result fails to match the strength of compacore® stacks.
Previous large-scale production of lamination stacks:
- Increased eddy current and interlaminar losses
- Compromised electromagnetic characteristics
- No inline quality control
Large-scale production of compacore® lamination stacks:
- Continuous process
- Chemical bonding
- No stacking and clamping of the stacks
- No subsequent curing in the oven
- Guaranteed electromagnetic characteristics that are measured inline