How Your Industry Can Benefit From Rotor and Stator Stacks

industry rotor stack

Rotor and stator stacks are essential components in electric motors, and their performance can make or break the motor's efficiency, performance, and longevity.

In this blog, we will explore the benefits and uses of rotor and stator stacks in various industries and what to look for when choosing a manufacturer for motor stacks. We'll also explore how, as a recognized leader in high-performance specialty alloy-based materials and process solutions, our team can help optimize these crucial components.

How Are Stators and Rotors Manufactured

Stator and rotor stacks are vital to electric motors. A stack transfers energy between the stator, the stationary part of the motor, and the rotor, the rotating part, thus allowing the electric motor to move. The manufacturing process for these stacks typically involves several steps.

First, the stator and rotor cores are made using lamination. A lamination is a thin sheet of soft magnetic alloy stamped or cut into a specific shape determined by the motor design. The laminations are coated with a thin layer of insulation and then stacked to create a solid core.

Next, the stator windings are wound around the stator core. The windings are typically made of copper wire and wound in a specific pattern to optimize the performance of the electric motor or generator.

For permanent magnet motors the magnets are either inserted into the rotor stack (for an IPM design) or bonded to an external surface of the rotor stack (for an EPM design). The rotor is then mounted to a shaft to complete the assembly.

Finally, the stator and rotor sub-assemblies are tested to ensure they meet their specifications and performance requirements before final assembly into the motor housing. At Carpenter Elefitrication, we use certain alloys to maximize the performance of electric motors and generators. Producing laminations and stacks from these high induction soft magnetic alloys requires the use of unique methods. Our Hiperco® alloys and stack manufacturing methods for dimensional control, high-strength, and tailored magnetic properties support the most demanding motor design requirements and production tolerances, resulting in superior motor responses.

Benefits and Use Causes of Stator and Rotor Stacks In Your Industry

Stator and rotor stacks are used to power motors in a wide range of industries, including electric aircraft, electric vehicles, aerospace, defense, consumer electronics, medical, energy, and industrial. Carpenter Electrification's Hiperco® stacks offer several advantages, such as improved efficiency, increased power density, reduced weight, and reliability. In terms of specifics, our rotor and stator stacks:

  • Offer up to 25% higher torque as a drop-in solution in current motor designs
  • Increase motor efficiency by up to 3% and power density by 30%
  • Can reduce footprint up to 30% with the same motor output in improved motor designs

This leads to energy savings, more compact motor designs, longer lifespans, and lower maintenance costs for every industry utilizing electric motor technology. Take a look at some industry-by-industry examples.

Electric Aircrafts: Electric aircraft are becoming increasingly popular due to their efficiency, environmental benefits, and ability to provide fast and point-to-point air transportation. Rotor and stator stacks are used in electric aircraft to power the electric motors that drive the propellers. These stacks provide a lightweight and compact solution for powering the aircraft. At Carpenter Electrification, our high-induction Hiperco alloys help electric aircraft designers to achieve high power density, high torque density, and reduced size and weight. 

Electric Vehicles: Consumers are increasingly switching to electric vehicles (EVs) over their traditional counterparts, gasoline-powered cars. Rotor and stator stacks power the electric motors that drive EVs. As more automakers introduce EVs with higher performance and comfort in mind, they’ll need more power dense electric motors. When it comes to the alloys and stacks to build high-power, torque-dense electric motors, no other solution can match ours.

Aerospace: Rotor and stator stacks are used in aerospace applications to build state-of-the-art aircraft integrated drive generators (IGDs), auxiliary power units (APUs), electric motors, and avionics. These stacks must provide a lightweight and compact solution for powering these systems, which results in an efficient and reliable aerospace system. We can help aircraft subsystems manufacturers reduce size and weight, improve power and torque, ensure continuous, extended use, and lower maintenance costs with our stator and rotor laminations stacks. 

Defense: Defense applications require motors operating in extreme conditions and delivering maximum power. Rotor and stator stacks are used to power the electric motors and and generators for robust military electric vehicles, naval submarines, warships, ground assault vehicles (GAV), unmanned aerial vehicles (UAV), and more. Our alloys can optimize rotor and stator stacks for these defense applications, resulting in robust and reliable motors that allow military forces greater mobility, agility, lethality, survivability, and reliability.

Medical: Medical devices, like handheld surgical tools, surgical robots, and ventilators, require motors that can operate in sterile environments and deliver precise performance. Our alloys can help enhance rotor and stator stacks used for these devices, resulting in high-torque, high-powered electric motors that are lighter, more responsive, and generate less heat. Stator and rotor stacks in these devices made with our best-in-class Hiperco® and Hypocore® alloys can also extend longevity, minimize maintenance or replacement costs, and ensure repeatable, high performance to put doctors and patients at ease.

Energy: Electric submersible turbines require pumps and offshore wind motors that can operate efficiently and reliably for long periods. Our portfolio of soft magnetic alloys and stacks provide industry-leading magnetic induction and the lowest core losses. They are used in highly efficient, compact electric motors that can reduce replacement operating expenses, minimize energy loss, maximize power output, and ensure reliable performance. 

Industrial: Industrial applications are varied and demanding. These motors must be able to operate in harsh conditions while delivering maximum power. Our rotor and stator stacks provide a lightweight and compact solution for powering these systems, which results in more efficient, precise, and reliable industrial equipment in manufacturing plants and beyond.

What to Look for In Motor Lamination Manufacturers

When looking for an electric motor lamination manufacturer, it is essential to consider several factors, including the following: 

  • Quality of products: Look for manufacturers who use high-quality materials and have a strict quality control process. This will ensure that the stator and rotor stacks you receive are reliable and perform well in your application.
  • Experience in the industry: See how long they have been in the business for and whether they have a proven track record of producing high-quality stator and rotor stacks. This experience will ensure they have the expertise and knowledge to deliver stacks that meet your requirements.
  • Ability to meet your needs: Try and find someone willing to work with you to understand your needs and tailor their products to meet those needs. This could include custom-designed stator and rotor stacks, special coatings, or other specialized features.
  • Lead time and delivery schedules: Check if the manufacturer can meet your time requirements for the product delivery.
  • Cost: Consider the product’s price, but also think about the long-term cost savings that a high-quality stator and rotor stack can provide.

In summary, rotor and stator stacks are crucial components of electric motors used across various industries, including electric aircraft, electric vehicles, aerospace, defense, consumer electronics, medical, energy, and industrial. The manufacturing process of stators and rotors, the benefits and use cases of rotor and stator stacks in different industries, and what to look for in motor lamination manufacturers are all essential factors to consider when sourcing for rotor and stator stacks. 

If you’re looking for a reputable and experienced manufacturer that checks all the above boxes, be sure to reach out to a member of our team.

Ready to speak to one of our experts?

Request a quote