Why Are Motor Stators Laminated? An Explanation

There are several approaches that can help optimize the performance and efficiency of electric motors, and the process of motor stator lamination is a great example. Why is electric motor lamination done, and what are the chief benefits that are found via this process?

At LCS Company, we’re proud to offer a wide range of custom electric motor lamination services, with motor lamination materials ranging from cobalt and nickel alloys to electrical steel, transformer steel and more. Here’s some basic information on why electric motor stators are laminated, including the immense value this process often provides to overall performance and efficiency for electric motors.

Converting Electrical Energy Into Mechanical Energy

One of the top functions of electric motor lamination is to allow the stator core to convert electrical energy into mechanical energy in an efficient way. This is the basis for how an electric motor operates and is crucial to the performance of machines that rely on them. Without proper lamination, energy losses in an electric motor would be high, leading to decreased efficiency and increased costs.

Reducing Eddy Currents

In addition to converting electrical energy into mechanical energy, laminating stator cores also helps reduce eddy currents. These are circulating currents that are induced within conductive materials when exposed to changing magnetic fields. In electric motors, eddy currents can cause excess heat generation and power loss, which can significantly impact their performance and lifespan.

By using laminated materials stacked together with insulation layers in between, these eddy currents are reduced. The insulation layers act as barriers, preventing the passage of eddy currents between the laminations. This results in a more efficient and durable electric motor.

Managing the Flow of Heat

Heat flow within an electric motor is also vital, and this is another area where electric motor lamination plays a crucial role. The laminated structure allows for efficient heat dissipation, preventing the motor from overheating.

As electricity passes through the motor, it produces heat due to the resistance of the wire and other components. If this heat is not managed properly, it can cause damage to the motor or even lead to a fire hazard.

The laminated structure helps to manage this heat by providing channels for air or liquid cooling systems. These cooling systems can dissipate heat away from critical components, ensuring that the motor operates at optimal temperatures.

Limiting Hysteresis Loss

Another key priority within electric motors is reducing energy waste caused by hysteresis loss. This type of energy loss occurs when the magnetic field in the motor lags behind its power supply, resulting in wasted energy.

To combat this issue, electric motors use laminated magnetic cores made from thin sheets of electrical steel. These sheets are coated with insulating material to prevent electrical currents from flowing between them. This design reduces hysteresis loss by allowing the magnetic field to easily alternate direction without lagging behind the current.

Improved Durability

Laminated stators offer significant structural integrity, making them more resistant to the high torque and vibrations of electric motors. This results in increased durability and longer lifespan for the motor.

Moreover, electric motor lamination offers resistance to damage caused by thermal expansion. This is because the laminated core is designed to combat any warping, which can negatively affect the motor’s performance and overall efficiency.

Reduced Noise

Laminated stators also contribute to a quieter and smoother operation of electric motors. The laminations help in reducing electromagnetic noise caused by the changing magnetic fields within the motor. This makes them ideal for use in applications where noise reduction is crucial, such as in household appliances or automotive vehicles.

Choosing the Right Lamination Material

As we noted above, there are several materials often used in electric motor lamination. A few examples, plus what they’re often ideal for:

• Cobalt alloys: Generally used for applications with high flux density requirements without saturation, cobalt alloys deliver great wear, corrosion and heat resistance.
• Nickel alloys: These alloys are highly permeable at low to moderate inductions, plus have low core losses.
• Electrical steel: Because of its fantastic conductivity, it’s often used to improve motor performance.
• Transformer steel: This is a type of electrical steel specifically meant for non rotation devices due to its magnetic properties.

As you can see, electric motor lamination holds major value in the manufacturing and performance of electric motors. These materials play a crucial role in ensuring high efficiency, durability, and reliability of motor systems.

At LCS Company, we’re proud to offer the best electric motor lamination services on the market. Contact us today to learn more about our products and services.

What You Need To Know About Aerospace Manufacturing

The aerospace industry pushes the boundaries of engineering, material science, and many other fields to bring innovations to modern conveniences. More than ever before, the world is so globally connected. People and goods move to and from different parts of the world with relative ease.

Not many individuals, however, think much about the small parts that make the big stuff seen possible. These small components are like the unsung heroes of aerospace manufacturing, making all the innovations and advancements possible. This resource provides an overview of two small but critical components of aerospace systems and why they are important.

Aerospace Motor Laminations

Creating the core of an aerospace electric motor’s stator and rotor requires laminations—thin metal sheets stacked together. Although they might be tiny in size, they contribute immensely to the proper operation of aircraft.

Motor laminations on aerospace components primarily help conduct magnetic flux, support motor windings, and reduce eddy currents. Eddy currents, also known as circular electric currents generate heat due to electrical resistance, leading to energy loss. This is undesirable in aerospace electric motors.

Considering how critical the roles they perform are, motor laminations must be manufactured with precise specifications and with specific mechanical properties in view.

LCS Company offers quality and precision-based motor laminations through the use of our on-site automation systems. This means we can produce extensive laminations or lamination segments that meet high standards set by regulatory establishments.

Other industries that benefit from motor laminations and we serve include X-ray manufacturing and power generation.

Aerospace Microstamping

Microstamping for aerospace as a form of die stamping involves making stampings on metal parts with sub-millimeter precision, barely invisible to the human eye.

Microstamped parts are designed for specific roles, including the facilitation of electrical connections between components. They are also used in supporting and securing parts within the aircraft. Microstamps can also fulfill additional roles such as anti-counterfeiting measures and unique coding.

One of the primary goals of the industry is reducing weight and increasing reliability. Etching small markings on metal parts helps reduce weight and size without sacrificing quality or strength.

LCS Company provides micro and miniature stampings for different applications, including aerospace manufacturing. We understand the nuances and complexities involved in producing parts in this size range. Tooling and engineering expertise always help us bring clients’ designs to life.

Because some stamping parts have complex workings, not all metal stamping companies have the human and system resources to make them correctly. Microstamping aerospace metals has never been a problem for us since fabrication solutions have been offered for years. Working on your project means putting all those years of experience and expertise into work for you.

Industries Served

The need for microstamped parts is not unique to the aerospace industry. Other major industries where etching small markings onto metal parts are needed are:

• Transportation
• Military and defense
• Energy and power generation
• Industrial & motion control

Choose LCS Company for Your Custom Laminations or Microstamping

We’re a trusted precision tooling company with an extensive understanding of design processes and practices in the industries above. Our metal stamping and motor lamination capabilities mean dependable results with accuracy and precision.

For questions about our services, don’t hesitate to contact us today.

How Motor Lamination Impacts Performances and Reliability

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.

How are Motor Laminations Made?

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.

Custom Metal Stamping

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.