Interlocking, Self-Bonding, and Riveting: Three Solutions for Stator Stacking

Stator stacking is a critical phase in the production of electric motors, where precision and quality determine the efficiency and longevity of the final product. Various techniques can be employed for this process, each with specific characteristics suited to different production needs. Among the most advanced and reliable methods are interlocking, self-bonding, welding, cleating, and riveting. Let’s explore the features of these three solutions and how to select the most suitable one to achieve a high-performance, durable electric motor.

Interlocking: Stability and Precision

Interlocking ensures a compact and stable assembly of stators through the application of pressure during the stacking process. This technique is ideal for industrial applications that require high mechanical strength and dimensional stability.

In this method, the silicon steel laminations are compressed and assembled with precision, forming a compact stator that guarantees exceptional performance. The result is a product with excellent rigidity and minimal dimensional tolerances, enhancing the motor’s efficiency and energy performance.

Press stacking is particularly suited for large-scale production, where repeatability and quality are critical.

Self-Bonding: Solid Bonding with Special Adhesives

Self-bonding is an innovative technique for stator stacking. This method involves applying a special insulating adhesive to the surfaces of the silicon steel laminations, which is then activated by heat. The process creates a solid, compact stator structure free of vibrations, eliminating the need for welding or clipping.

The primary advantage of self-bonding is its ability to enhance the motor’s electrical and mechanical performance by reducing the gaps between laminations and minimizing potential magnetic losses. This solution is ideal for applications requiring quiet operation and optimized energy efficiency. Additionally, self-bonding is highly flexible and can adapt to various stator configurations.

Welding: Robustness for Large Applications

Welding is one of the most used methods for stator stacking due to its ability to provide stable and durable assembly. In this process, laminations are precisely welded together, creating a solid and robust structure.

Different welding techniques are available, including inclined welding, which is particularly suitable for stators with complex geometries. This method is appreciated for its versatility and adaptability to various production configurations, making it an excellent solution for large motor designs.

Cleating: Speed and Efficiency

Cleating is a cost-effective and fast method for stator stacking. This technique uses metal clips to secure the laminations, ensuring stability and compactness.

While simpler than other methods, clipping delivers excellent results in terms of production speed and overall product quality. It is particularly well-suited for medium-scale production, where time and cost efficiency are critical factors.

Riveting: A Traditional and Reliable Solution

Riveting is one of the most established techniques for stator stacking. In this process, laminations are assembled and secured using metal rivets, providing stability and mechanical resistance.

This method is valued for its simplicity and reliability, especially in medium-scale production or applications that do not require extensive customization. Riveting offers the advantage of a quick and efficient assembly process, reducing production times and maintaining competitive costs. Despite being a traditional method, it remains a dependable choice for ensuring a sturdy stator structure.

Choosing the Right Solution

Selecting the appropriate stacking technique depends on several factors, including specific design requirements, production volumes, and the desired characteristics of the final product. Interlocking is ideal for large-scale production with tight tolerances, while self-bonding is perfect for motors demanding high energy efficiency. Welding and clipping provide versatile and reliable solutions for various production configurations.

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