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Author Archives: Josh Gardner

  1. How Motor Lamination Impacts Performances and Reliability

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    Have you ever wondered what it takes to get a motor running and why different motors perform differently? Believe it or not, laminations are one of the primary reasons behind these differences. Motor lamination significantly impacts both performance and reliability—but what is motor lamination in the first place?

    If you want to learn how these critical components work and how they can affect your motor’s performance and longevity, let’s start from the basics, such as its material selection and joining process and considerations. These will help you make an informed decision as you choose a motor lamination that will provide optimal results for your immediate needs.

    Understanding What Motor Laminations is About

    Motor laminations comprise thin metal sheets bonded, stacked, or welded together. These steel portions are found or form the core of a motor’s stator and rotor. 

    Custom motor laminations can be configured according to the specific requirements of their end application. However, choosing the suitable steel material for its production is imperative as it influences the motor’s performance, efficiency, cost, and weight.

    Two of the most popular are silicone and transformer steel, which are a type of electrical steel:

    Silicone steel

    When silicone is added to the steel, its electrical resistance increases, allowing magnetic fields to penetrate it easily. It also reduces the steel’s hysteresis loss.

    Transformer steel

    A type of electrical steel with remarkable magnetic properties, these are specialty steels primarily designed for non-rotation devices.

    Since electrical steel is formed through the cold-rolling process, the best variation for this type would be CRML or cold-rolled motor lamination. These provide tons of benefits that can improve the performance of motor laminations.

    Some advantages of cold-rolled motor lamination steel:

    • Tailored to create electromagnetic core materials for electrical equipment
    • Better thickness, shape, dimension, and surface finish since cold rolling allows for better control
    • Minimum eddy current loss

    The joining and tempering process also affects the overall performance of motor laminations. Determining the best method for motor laminations will highly depend on the application it is designed for and the type of components used. For instance, motor laminations for brushless motors are usually annealed under controlled conditions to minimize distortion.

    The Best Joining Process for Laminations

    The joining process of motor laminations will also impact its overall efficiency. There are two different methods you can choose from, which are as follows:

    Bonding

    Bonding offers numerous advantages. It utilizes a roll coat method where a high-performing adhesive is applied to the lamination sheets after a cutting process.

    Benefits of bonding:

    • Cancels the need for welding or using rivets, as these can cause interlaminar loss
    • Maximum thermal conductivity
    • No humming noise
    • Wide range of adhesives to choose from
    • It can be used without heat input

    Welding

    Welding joins stacked laminations using fiber optic lasers. The concentrated heat sources allow for narrow and deep welds.

    Benefits of welding:

    • Electrodes are in contact with the parts
    • Compresses the product to measure force and movement
    • Improved process control

    Between bonding and welding, motor lamination bonding is the best option for most applications because it offers the best performance, reliability, and cost. Plus, it does minor damage that ensures minimal losses.

    Custom Motor Laminations for Your Specific Applications

    Custom-made motor laminations provide better results for more specific project applications and requirements. You have complete control of the material and joining process to ensure maximum performance and reliability for your motor.

    At LCS Company, custom solutions are available whether you need lamination steel for rotational or non-rotational device applications. Contact us today so that we can find the best solution available. For large volume orders, request a quote to receive the most competitive price.

  2. How are Motor Laminations Made?

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    Are you ever curious about how your car’s electric motor runs? Have you ever wondered what makes it move or how those small motors in kitchen appliances run? It all starts with motor laminations.

    A motor lamination is the core of every motor and helps power everyday objects from computers to refrigerators, making them function properly. Let’s dive into what motor laminations are, the process of how they’re made, and why they’re important for cars and other machines that rely on electricity.

    What are Motor Laminations and their importance?

    Motor laminations are a crucial component of an electric motor. They allow the motor to be more efficient and reliable by reducing losses in energy due to eddy currents, hysteresis, and core loss.

    As the name implies, motor laminations are made of thin steel sheets stacked and clamped together to form an electrical machine’s stator or rotor core. The steel laminations reduce the total amount of material used in the construction of the motor while creating a low-resistance path for current flow that reduces eddy current losses in the motor’s windings.

    Understanding the Process of Motor Lamination Manufacturing

    Here’s the guide on the process of motor lamination fabrication:

    1. It begins with selecting an appropriate core material. The most common materials used are cold-rolled grain oriented (CRGO) silicon steel for cold rolled motor lamination, which is durable and efficient in electrical conduction. Other materials such as ferrite, amorphous metal alloys, or composites may also be used depending on the design requirements.
    2. Once the core material has been selected, the next step is to cut it into individual laminations that will form the stator and rotor components of the motor. This is typically done by a punch press machine, where sheets of precut material are placed on a die plate and then pressed against a set of tools to cut out each lamination individually.
    3. The laminations are then stacked in an alternating pattern, creating an even number of poles. The stack is then pressed together to form a single solid unit which can be used as the stator or rotor core. The stack is aligned and clamped tightly before being subjected to a heat treatment process that helps in motor lamination bonding layers together and ensuring electrical conductivity between them.
    4. Once the motor lamination has been formed, it is ready for further processing. This includes adding insulation layers, winding wires, and attaching other components such as magnets and commutators. After complete assembly, the motor lamination can be tested to ensure its performance meets or exceeds design specifications.

    Benefits of Motor Laminations

    Motor laminations are essential components of electric motors and generators, as they are responsible for insulating the electrical windings from one another. This makes them invaluable to any electric motor or generator construction project.

    1. One of the primary benefits of motor laminations is their ability to reduce energy losses due to eddy currents. By creating multiple winding layers separated by thin metal sheets, the eddy current created by alternating magnetic fields can be greatly reduced, allowing for more efficient motor operation. In addition, this reduces noise pollution due to decreased vibration levels.
    2. Another benefit of motor lamination is its lightweight and small size compared to other materials used in electric motor designs. This makes them suitable for various applications, from small, hand-held electric motors to large industrial machinery. Additionally, their low cost compared to other materials makes them the preferred choice of electric motor designers.
    3. Motor lamination is also beneficial for temperature changes. When electricity passes through metal sheets, heat is generated. This additional heat can be detrimental to the motor’s operation and performance. Motor laminations help reduce this risk by providing insulation for consistent temperature throughout the entire motor.

    Our most reliable motor laminations from LCS Company

    LCS Company offers a wide range of motor lamination services, from standard brushless motor laminations to custom options and more built to your exact specifications. Our experienced team uses the highest quality materials and precise standards to ensure that each lamination is perfectly manufactured for maximum performance and longevity. Contact us today, and let us help you find the ideal motor lamination solution for your next project.

  3. Custom Metal Stamping

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    Metal stamping is a manufacturing process that creates quality metal component parts using extremely precise custom tooling. At LCS company we cater to a wide range of industries to meet specific and varying program parameters.

    Our custom services can deliver superior outputs that will meet and exceed product quality requirements. At LCS company we’re committed to providing customer success.

    Custom Metal Stamping Done by Experts

    We have over 65 years of experience in precision metal stamping, these extensive years of experience allow us to engineer solutions to fit your product workpiece requirements. Our in-house facility is equipped with fully automated presslines and in-house tool & die supporting our metal stamping production.

    There are various metal stamping services that can be achieved through different techniques. Services differ in how they are completed and a customer’s desired results. Here are the different metal stamping techniques that we offer:

    • Blanking: Blanking refers to removing stamping metal using a die to achieve specific shapes. The removed material sometimes becomes the desired workpiece.
    • Coining: This technique involves moving the raw material within a workpiece to a new desired location, by means of material displacement.
    • Punching: A material is removed from the metal workpiece as the punch enters a die, leaving a hole.
    • Embossing: The raw blank is pressed against a die in this process to make a recessed or raised pattern.
    • Drawing: A specialized custom metal stamp that stretches the workpiece around a radius to achieve a cup or dome shape with the material.
    • Bending: It’s the general technique of bending the material into L, U, or V shapes and typically occurs in a single axis.

    Common Applications of Metal Stamping

    With our quality metal stamping services, we can work according to the needs and requirements of our customers. We can produce components for various sectors, such as aerospace parts, automotive components, medical devices, and consumer electronics.

    Here are some common applications:

    • Household appliances
    • Motor mounts
    • Friction plates
    • Medical devices
    • Structural components
    • Industrial machinery parts
    • Fasteners

    These are just typical applications that can be achieved through production metal stamping. It’s also commonly employed to achieve complex three-dimensional designs or incredibly detailed small parts.

    Compelling Benefits of Metal Stamping

    Many industries rely on custom metal stamping because it’s cost-effective and highly repeatable. It’s applicable for low, medium, and large-volume runs while ensuring consistency across all finished products.

    Here are other advantages:

    • Significantly reduced production costs
    • Reduces the need to utilize multiple machines
    • Ideal for bulk orders
    • High flexibility due to customization freedom
    • Incredible accuracy and precision
    • Easily Repeatable

    Metal stamping is ideal if you’re looking for a fast and reliable method of acquiring thousands to millions of workpieces with exactness. At LCS Company, we have the right equipment to complete your project cost-effectively and with superior outcomes.

    Trust Us to Fulfill Your Metal Stamping Needs

    LCS Company is the go-to source for high-quality parts and components while employing different metal stamping methods. With our expertise and years of experience, you can trust us to take control of your project and deliver excellent outcomes.

    Contact us now to learn more about our services. Request a quote, and we’ll find a solution that won’t break the bank.

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