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Manufacturing stators and rotors for electric machines
An electric motor is the heart of any modern machine. Its stable operation depends on a quality electric motor stator, a reliable windings and precision assembly rotor.
Asynchronous electric motors consist of a stator and a rotor.
Stator is a stationary part of an electric motor that works in conjunction with the rotor. It consists of a base (housing) and a core made of electrical sheet steel 0.35–0.5 mm thick. Inside the stator are slots for housing the windings, which form an electromagnetic field when current flows through them. The stator housing is typically made of aluminum or cast iron, ensuring the strength and durability of the construction.
Stator winding — is a multi-turn coil of enameled copper wire. In asynchronous motors, it is placed in the grooves of the core and connected in a «star» or «delta» configuration.
The stator winding is responsible for creating the rotating magnetic field and is powered by a three-phase current, thus generating a rotating magnetic field.
Stator resistance It depends on the material and cross-section of the wire, which affects power loss and heating.
Stator rewinding includes removal of old winding, cleaning of slots, winding of new winding, and varnishing.
Where can I buy a stator? Order stator manufacturing or rewinding from us – full cycle, quality guaranteed!
Stages of electric motor production
Slitting and varnishing of electrical steel
Steel cutting is performed on special equipment—a guillotine. Next, the steel elements are thoroughly dried to remove moisture, then coated with a special electrical insulating varnish.
Varnishing the surface of the plates is done for subsequent sintering together. After assembling the package of plates, it is tightened with a certain force and transferred to the next stage – welding in a furnace.
Sintering of plate packages
The prepared plate pack is placed in a furnace to heat the varnish and thereby bond the plates together. After this operation, the stator construction becomes monolithic. The varnish polymerizes upon heating and forms a strong insulating film.
This processing complex prevents interlayer currents, reduces eddy current losses, and increases the service life of electrical equipment.
Electrical discharge machining
The cooled plate pack, after the furnace, goes to the machine. Electrical discharge machining, where is it happening groove cutting operation of the required diameter according to the electric motor designer's technical specification.
If necessary, we apply a coating to the stator on our own line. powder coating.
Coil group winding
After receiving the necessary shape and dimensions, the stator base enters the winding machine. The winding process involves laying turns of enameled copper wire into a special jig with several grooves, which ensure the correct placement of the coils.
After the winding is completed, the entire coil assembly is removed from the mandrel and placed into the machine's core slots. This method enhances the accuracy, reliability, and productivity of winding manufacturing, especially when automating the process.
Rotor magnet insertion and assembly
Before gluing the magnets, the surface must be thoroughly cleaned and degreased. Heat-resistant epoxy adhesive is used, and the operation must be performed with strict observation of polarity and correct magnet positioning.
Next, the rotor is installed, balanced, electrical tests are performed, and final assembly is completed.
Typical electric motor malfunctions
Corrosion and pollution
rust, rotor seizure, need for disassembly and cleaning
Insulation damage
Ingress of dust, dirt, metal shavings — inter-turn short circuits, overheating, shaft deformation
Problems with windings
Short circuit, smoke, humming, need to rewind the stator
Overheating and vibrations
Overload, ventilation failure, bearing failure, imbalance
Malfunctions when operating from frequency converters
insulation breakdown, filtration required
You can order stator manufacturing or rewinding in Moscow from us.
Send a drawing or model, and we will calculate the cost and manufacturing time, as well as suggest optimal parameters to reduce the cost and increase the lifespan of the electric motor.
Our production capabilities and skilled personnel allow us to manufacture stators and rotors for electrical machines of various sizes.
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