High-performance Stator Based On Additive Manufacturing Technology

High-performance stator based on additive manufacturing technology

Motors are an indispensable and important component in modern industry, and the performance of motors often depends on the quality of the stator, which is usually made of silicon steel sheet material. Additive manufacturing is an emerging manufacturing technology that can create more complex structures while significantly shortening product development cycles.Fe-3wt.%Si ferritic material has excellent magnetic and mechanical properties, which can greatly improve the performance of the motor, while the electrocathorate is lower than that of traditional silicon steel sheet, and the electrical properties are better. Therefore, the use of additive manufacturing technology and Fe-3wt.%Si ferritic material to manufacture motor stator has great significance and application value.

Recently, TeiN. Lamichhane and other researchers from Oak Ridge National Laboratory in the United States have carried out research on additive manufacturing technology and Fe-3wt.% Si ferrite material to manufacture motor stator, which can not only realize stator manufacturing of complex shapes, but also have higher flexibility and customizability.

At the same time, it can greatly shorten the product development cycle and improve production efficiency, and this research has been supported by the US Department of Energy and is a very promising technical research.

The stator is printed by selective laser melting technology, then processed into thin layers, and finally superimposed into a stator core. Selective Laser Melting (SLM) technology was used to print Fe-3wt.%Si ferritic materials. SLM technology is an additive manufacturing technology for base dry powder materials, which is melted and stacked layer by layer by laser beam to form the desired three-dimensional structure.

Compared with traditional manufacturing methods, SLM technology has higher flexibility and customizability, and can manufacture more complex structures: Fe-3wt.%Si ferrite material is a material with excellent magnetic and mechanical properties, which can greatly improve the performance of the motor. At the same time, the electro-cathorate of the material is lower than that of traditional silicon steel sheets, and the electrical properties are better. The application of this material can bring higher performance and better efficiency to the motor manufacturing industry.

Figure 1: First layer of photographs printed during SLM (left): Seven Fe-3wt.%Si stator samples completed (right)

Figure 2 Motor components: (a) SLM printed stator and cylinder; (b) 1.4mm thickness stator sheet: (c) assembled stator winding: (d) rotor with BAAM printed NdFeB-PPS magnet; (e) assembled rotor; (f) housing rotor; (g, h) complete set of motor.

The study also tested the properties of the printed materials and compared them to conventional silicon steel sheets. The results show that the magnetic permeability of the stator is more than 20% higher than that of traditional silicon steel sheet, and the magnetic saturation induction intensity is also more than 10% higher than that of traditional silicon steel sheet. At the same time, the strength and hardness of the stator are much higher than that of traditional silicon steel sheets, and the Shenyin rate is also lower than that of traditional silicon steel sheets, and the electrical properties are better. This increase in performance can lead to higher efficiency and better performance in the motor manufacturing industry.

Table 1 Comparison of magnetoelectric properties of conventionally machined electrical steel and SLM AM Fe-3wt%Si laminate.