Yuma Precision Brushless Motor Cores: The Power Core of High Efficiency and High Reliability
Leveraging its extensive manufacturing expertise accumulated in the servo motor field, Yuma Precision has extended its precision manufacturing capabilities to the field of Brushless DC (BLDC) motor cores. We deeply understand that a brushless motor core is not only the carrier of the magnetic field, but also the structural foundation that determines motor efficiency, torque output, and long-term reliability. Through full-process deep customization from raw materials to finished products, we provide customers with high-performance, widely adaptable brushless motor core solutions.
I. Core Design Features and Technical Advantages
The core of brushless motor core design lies in optimizing magnetic circuit efficiency, reducing losses, and ensuring stability under high-frequency commutation. Yuma Precision achieves technological leadership through the following key features:
1. High-Efficiency Magnetic Circuit and Low-Loss Design
Optimized slot and pole matching: Through electromagnetic field simulation, tooth profile, slot opening width, and pole arc coefficient are precisely designed to maximize air-gap magnetic flux density while minimizing cogging torque and iron loss, ensuring smooth and efficient motor operation.
High-performance magnetic materials: According to motor speed and efficiency requirements, different grades and thicknesses of non-oriented silicon steel laminations are selected (such as 0.2 mm, 0.35 mm, and 0.5 mm).
2. High Structural Strength and Thermal Optimization
Mechanical load-bearing design: The core structure is verified through mechanical analysis to withstand centrifugal forces from high-speed rotor rotation, electromagnetic forces, and possible axial loads, ensuring structural integrity under harsh operating conditions.
Integrated heat dissipation paths: Unique tooth and yoke designs not only optimize magnetic flux but also consider heat conduction paths. Combined with housing design, they enable efficient heat dissipation and prevent performance degradation caused by excessive temperature rise.
3. Precision Manufacturing for Automated Production
High consistency assurance: Precision stamping and interlocking lamination processes ensure accurate positioning of each silicon steel sheet, resulting in a high and consistent stacking factor, fundamentally guaranteeing uniform motor performance in mass production.
Winding-friendly structure: Precisely controlled slot dimensions and smooth inner slot walls (burrs ≤ 0.02 mm) facilitate subsequent automated winding processes—whether flyer winding or needle winding—improving production efficiency and slot fill factor.
II. Yuma Precision Process Chain Empowerment: From Core to Ready-to-Use Assemblies
Yuma Precision not only supplies motor cores, but also delivers highly integrated process solutions that significantly enhance customer production efficiency and product reliability.
Segmented (split) core technology: For large-sized stators or complex slot geometries, segmented stator cores are available. This design allows winding before assembly, greatly improving winding speed and slot fill factor, making it especially suitable for mass production of high-efficiency motors.
Integrated insulation and structural processing: Customized insulation bobbins (formers) can be inserted, providing reliable slot and phase insulation while accurately guiding the winding process.
Winding and welding services: We offer precision automated winding and terminal welding services, delivering fully wound stator assemblies that customers can directly assemble, simplifying the supply chain.
Overall encapsulation and protection: For applications requiring high environmental reliability, potting compounds can be applied to fully or partially encapsulate the wound stator, enhancing heat dissipation, moisture resistance, corrosion resistance, vibration resistance, and mechanical fixation.
III. Typical Application Cases
Thanks to high efficiency, long service life, and excellent speed regulation, brushless motors are widely used in the following fields, with Yuma Precision providing their core motor core support:
1. Power Tools and Home Appliances
Applications: High-speed angle grinders, electric drills, cordless vacuum cleaners, inverter air conditioner compressors, and direct-drive motors for drum washing machines.
Core requirements: High power density, high speed, low cost, and long service life.
Yuma solution: Using 0.35 mm / 0.5 mm high-performance silicon steel laminations, optimized for high torque output; providing integrated segmented cores with automated winding to enable fast, cost-effective mass production.
2. Automotive Components
Applications: Electric water pumps, electric oil pumps, electric air conditioning compressors, cooling fans, and power window motors.
Core requirements: Automotive-grade reliability (high-temperature resistance and long lifespan), low noise, and high efficiency.
Yuma solution: Utilizing low-loss silicon steel laminations of 0.5 mm / 0.35 mm / 0.30 mm / 0.27 mm / 0.2 mm, with anti-oxidation and enhanced insulation treatment. Temperature sensors can be integrated, and overall potting solutions provided to meet harsh engine compartment conditions.
3. Fan and Pump Industries
Applications: Industrial cooling fans, EC centrifugal fans, circulation pumps, and booster pumps.
Core requirements: High efficiency for energy saving, wide speed regulation range, and low vibration and noise.
Yuma solution: Magnetic circuits optimized for fan load characteristics to reduce iron loss at low-load operation; multi-pole design options for smooth low-speed performance. Cores can be combined with dynamic balancing processes to control vibration at the source.
4. Drones and Model Applications
Applications: Aerial photography drone motors, FPV drone motors, and model car / outrunner motors.
Core requirements: Extreme lightweight design, ultra-high speed, and high instantaneous overload capability.
Yuma solution: Using 0.2 mm ultra-thin silicon steel laminations or thinner materials to reduce iron loss and weight; designing high slot fill factor slots combined with Litz wire winding to reduce high-frequency losses; providing high-precision, high-strength stator core assemblies for outrunner motors.
IV. Deep Customization Options
Yuma Precision provides comprehensive customization services tailored to your specific application requirements:
1. Material Customization
2. Dimensional and Structural Customization
Outer / inner diameter: From Φ10 mm to over Φ150 mm.
Stack height: Flexible customization based on power requirements.
Slot and pole combinations: Multiple configurations available (such as 9 slots 6 poles, 12 slots 8 poles, 24 slots 22 poles, etc.).
Core types: Inner-rotor stator cores, outer-rotor stator cores, and various special-shaped structures.
3. Process and Functional Integration Customization
Insulation systems: Customized insulation paper or bobbins with different thermal classes (Class B, F, H) and thicknesses.
Winding solutions: Support for concentrated windings and distributed windings, with various wire gauges and winding methods.
Fixation and processing: Options include self-interlocking, TIG welding, clinching, riveting pins, or adhesive potting for lamination fixation.
Embedded components: Pre-embedded mounting seats for Hall sensors, temperature sensors, or positioning pins.
Conclusion
Yuma Precision’s brushless motor core solutions are rooted in a deep understanding of electromagnetic principles and precision manufacturing processes. We are not merely a stamping and lamination supplier, but a full-chain partner capable of delivering magnetic circuit design, material selection, precision manufacturing, and pre-assembled components. Whether for cutting-edge innovative products pursuing ultimate performance, or large-scale applications demanding high cost-effectiveness and reliability, Yuma Precision provides the professional customization capabilities to power your brushless motors with a strong and reliable “heart.”
