Laminated Soft Iron Cores Manufacturer

Our studies show that it’s very important to control how thick the layers are to lower the eddy current losses. While making the layers thinner (down to 0.18–0.23 mm for high-frequency jobs) greatly reduces these losses, it also makes them harder to build because it’s tricky to handle and cut very thin materials. We’ve bought special tools and created new methods to handle these problems. This lets us make super-thin layers for tough jobs like EV traction motors and high-frequency transformers.

The stacking factor is a number that tells you how much of the core is actual magnetic material compared to its total size. It’s usually between 0.92 and 0.97. We are always trying to make this number higher by using better coatings. Our inorganic phosphate and organic hybrid coatings are made to make the interlaminar gaps (gaps between layers) as small as possible and the insulation thinner. This gives more room for the magnetic field to work and makes the core perform better.

We make cores in different shapes, and each shape is good for different things:

• Toroidal Cores: These are the most efficient and leak the least amount of magnetic field because they are a closed-loop shape. But they usually cost more to make because they are hard to wind and put together.
• E-I and U-I Cores: These are the most popular choice when cost is important. They are easy to make in large numbers and can be stacked by machines.
• C-cores: These are a good choice for special orders, small batches, or when you need something very reliable, like for aerospace. They offer a lot of design freedom.

Our team helps customers pick the best shape for what they need, finding the right balance between performance, price, and how easy it is to make.

Getting the size of the core’s window and legs just right is very important. It helps balance how much copper wire can fit (copper fill factor), how well it cools down, and the strength of the magnetic field (magnetic flux density). We use smart computer programs to look at many different design options and find the best ones. Doing this can make the electrical machines much more efficient by making sure the wires are placed well and heat can escape easily.

We are looking into using Additive Manufacturing (AM), also known as 3D printing, to make early test versions of our cores. Studies show that methods like binder jetting and laser powder bed fusion can be used to print complex laminated soft iron cores right on the spot, with magnetic properties made just for a specific job. Making lots of them this way is still hard and expensive. But AM gives us amazing freedom to create special, high-performance core designs when we are making early test versions (prototypes).

We know our customers have different budgets to work with. We use a method called life-cycle cost analysis (LCCA) to show why spending more money at the start on better materials and building methods is a good idea. The money saved over time from using less energy and needing fewer repairs often makes up for the higher price at the beginning. This makes it a great deal in the long run.

We care about the environment and try to use sustainable methods. More and more, people are using recycled electrical steel and creating manufacturing systems where waste is reused. We make sure our work has as little impact on the environment as possible, and our products are designed to be recycled, following international environmental rules. With the right heat treatment (re-annealing), recycled materials can work just as well as new ones.