Our Motor Design Technology

We believe that only a great motor can drive innovation

Magnet Free

Lower cost, more sustainable, higher temperature resistance, more efficient, less supply risk when compared to permanent magnet motors.

Segmented Stators

Our segmented stators assembles the stator from a number of sub-stacks rather than a a single stator. This leads to a simplified manufacturing process, less material usage and smaller air gaps.

Bonded Laminations

Thiner steel laminations bonded together allow for lower losses within the lamination stack

Magnet Free

Technelec’s experience in designing and simulating magnet free designs, and eventually putting magnet free motors into production puts us in the right place to help your magnet free designs.

We also optimise the motor characteristics for your application, using simulations on use cases to ensure that the product will remain at peak efficiency throughout its lifetime. We have achived up to 10% efficiency savings in this optimisation process alone.

  • Easier to recycle, as they do not contain permanent magnet rare-earths such as neodynium and dysprosium which can contribute significantly to the end-of-life cost of a product.
  • Better temperature resistance. Permanent magnet motors have an upper temperature limit of 120°C – 150°C beyond which the magnet becomes demagnetised at high current and the motor breaks.
  • Lower cost. Rare earth magnets are expensive to extract and recycle.
  • Less supply risk. The rare earth market is almost entirely dominated by China leaving the product vulnerable to price gouging.

Segmented Stator

Our segmented stators assembles the stator from a number of sub-stacks rather than a a single stator. The stator can be broken down into segments in a number of different ways.

  • a segment comprising an entire tooth where adjacent segments are interconnected in the back-iron
  • individual teeth are inserted into a single annular lamination
  • the pole-shoes of each tooth are separately inserted in the stator core

Segmented stators are an innovation in motor design which leads to:

  • Lower manufacturing costs. The winding process becomes much easier to perform and tighter windings can be achieved.
  • Less material wastage as no large stator laminations must be punched.
  • Higher torque. Segmented stator have the potential to have a smaller air gap and as the air gap width is no longer determined by the limitations in the punching tool. This leads to improvements in air gap flux, and hence torque of the motor.

Bonded Laminations

There are two traditional ways of creating lamination stacks:

  • Interlocking: using small reliefs in the lamination to bind it to adjacent laminations.
  • Welding: high temperature process to join laminations metal to metal.

Bonded laminations uses a backlack coating on each lamination which is cured after punching to create a bonded stack.

  • Avoids welding and interlocking. The welding process destroys magnetic properties in the region of the weld, as does interlocking the laminations.
  • Quieter. The compliance in the lamination stack absorbs mechanical resonances.
  • More efficient. Maintains the magnetic properties as it avoids destructive binding techniques.