The Thinner the Lamination, the Better the Motor Performance?

When it comes to motor design, how much do material thickness and lamination play a role in efficiency and performance? As engineers and designers know, the stator and rotor core material significantly affect an electrical machine’s output, heat dissipation, weight, and cost. But does thinner always mean better?

Thinner materials often lead to lower high-frequency eddy current losses, improving motor efficiency and reducing power consumption. This can result in longer transmission distances for the same electrical capacity—a critical factor for electric vehicles (#EVs) where even small gains in efficiency can significantly impact battery range.

However, thinner laminations aren’t without challenges. For instance, thinner steel sheets require more laminations to achieve the same total height. This increases stamping time, reducing production capacity. For example, a 0.25mm sheet can take 1.7 times longer to process than a 0.35mm sheet for the same motor stator core.

Beyond manufacturability, the choice of material depends on multiple factors, including cost, permeability, electromagnetic losses, and application-specific requirements. While extremely thin core steel improves efficiency in high-speed motors, particularly in the stator, the rotor often demands higher strength over thinner materials.

So, is thinner better? The answer lies in striking the right balance. A comprehensive analysis considering manufacturability, efficiency, cost, and application-specific demands is essential when choosing core materials for motor design.

Want to dive deeper into the trade-offs and material selection strategies for optimal motor performance? Read the full article here at Quadrant Technical Insights-Striking the Balance: How Lamination Thickness Impacts Motor Performance.