The internal stator of a brushless motor is one of the key components within a brushless motor, working in conjunction with the rotor to form the motor’s power system. The internal stator of a brushless motor primarily consists of coils and a core, with the coils wound around the core. When electrified, it generates a rotating magnetic field, providing the necessary power for the motor and ensuring its stable operation.

 

There are various winding techniques for the internal stators of brushless motors, such as the Wired Stator, the Pierced Stator, and the Wound Stator, among others. The details are as follows:

 

A.Wired Stator

 

The wired stator achieves an efficient and stable connection with external power sources or control systems through terminal connectors, providing a strong guarantee for the normal operation of the circuit and the stable functioning of the equipment. In the manufacturing process, through a series of meticulous assembly processes and welding techniques, we ensure the production of high-quality products. Details are as follows:

 

1.Assembly the anti-pull-through side and the lead-through side insulating bracket supports, press the pins into the insulating brackets to prevent misinsertion, skew insertion, or incomplete insertion, greatly enhancing the reliability and durability of the product.

 

2.Wide compatibility range for conventional wire diameters: Our internal winding equipment is compatible with a wide range of wire diameters from 0.1 to 1.2mm. We provide custom winding machine services for special requirements. Moreover, our internal winding machine can automatically complete the processes of winding, hanging, slot changing, cutting, and feeding of enameled wire, ensuring product consistency.

 

3.Spot Welding: In the field of resistance spot welding technology, HONEST offers a precise and efficient welding solution to ensure a secure connection between the copper wire and the terminal. Our welding process strictly adheres to welding quality requirements, including achieving a melting bond between the enameled wire and the terminal, controlling the deformation of the enameled wire after welding to between 30%-50%, and ensuring the structural integrity after welding to avoid frame deformation, damage, and terminal skewing.

 

4.Performance testing: Product quality is our core focus. Key quality indicators such as turns, resistance values, pinholes, and wiring are comprehensively tested to ensure that the product performance meets design requirements and to ensure product consistency and reliability. We offer three types of tensioners for customers to choose from servo, electronic, and mechanical, configured according to the actual production needs of the customer to achieve the best winding effect and production efficiency.

 

5.Customized services: We offer flexible plan customization services, which can be configured according to customer needs for monitoring mechanisms such as pressure, displacement, batch codes, welding energy, and welding time, ensuring a smooth production process and compliance with quality requirements.

 

 

 

B.Pierced Stator

 

The pierced stator is a key component in brushless motors, working in synergy with the rotor to form the motor’s power system. It is primarily composed of coils and a core, with the coils wound around the core. When electrified, it generates a rotating magnetic field that provides the necessary power for the motor and ensures its stable operation. The pierced stator’s winding process eliminates the cumbersome step of stripping the enamel and effectively prevents issues such as oxidation and false welding. Additionally, by flattening the surface of the core, it eliminates irregular shapes and burrs, thereby improving the stator’s magnetic conductivity and efficiency due to its no-enamel-stripping, oxidation-prevention, and other benefits.

 

C.Wound Stator

 

The wound stator is a specially designed motor stator, characterized mainly by the arrangement of the stator coils. The type of stator utilizes a unique coil layout, where copper wire is wound onto the stator core to form a compact coil structure, presenting a coiled shape.

 

Advantages of HONEST Wound Stator:

 

1.In the process of manufacturing, our equipment is highly automated, capable of automatically inserting into nine slots, and controlling key parameters such as slot liner length and core fitting.

 

2.The winding process of the enameled wire is completed by the internal winding machine, with precise settings for key parameters such as the number of turns, winding speed, and winding tension, ensuring high standards and consistency in the winding process. The program interface has a locking mechanism, with operators having no permission to change, which can provide the stability of the production process and the standardization of products. Moreover, the core is positioned and controlled by using jigs and positioning pins, effectively preventing misplacement and ensuring the accuracy of the process.

 

3.Performance Testing: To ensure that the stator meets the process requirements after the coil winding is completed, key parameters such as resistance, insulation, turn-to-turn, withstand voltage, and direction of rotation are 100% fully inspected for quality and performance, ensuring the consistency and reliability of the product.

 

 

 

The Market Analysis for Brushless Motor Internal Stators

 

The market analysis for brushless motor internal stators, which are a core component of brushless motors, can be examined from several perspectives based on the data available for the year 2024:

1.Market Size and Growth Trends: According to an analysis, the global market size for brushless DC motors was nearly 20 billion USD in 2023, and is expected to continue growing. This indicates a strong potential for growth in the brushless motor market on a global scale.

 

2.Expansion of Application Fields: The application of brushless motor internal stators is particularly prominent in the electric vehicle and hybrid vehicle market. It is anticipated that with the global increase in environmental protection and energy efficiency requirements, the growth in the sector will drive an increase in demand for brushless motors.

 

It’s worth noting that technological advancements and cost reductions in raw materials and production scales are contributing to the improved cost-effectiveness and market acceptance of brushless motors.

 

In all, the brushless motor internal stator market is poised for expansion, driven by technological progress and growing applications across various industries, with a particular emphasis on the electric and hybrid vehicle markets. Companies will need to focus on technological innovation and adapt to market changes to maintain a competitive edge.

 

Taking into account multiple dimensions such as manufacturing processes, connection methods, and the level of equipment automation is crucial for achieving efficient and stable connections in brushless motor internal stators. Wired stator, pierced stator, and wound stator each have their unique process characteristics and advantages, allowing customers to choose based on actual production needs and specific application scenarios.

 

The wired stator, with its stable connection and meticulous assembly process, is suitable for applications that require high connection stability. The pierced stator, with its innovative connection method, simplifies the process flow, improves production efficiency, and effectively controls costs. The wound stator, with its high power density and compact structure, is suitable for applications with space constraints and high-performance requirements.

 

The specialized program customization service provided by HONEST is one of the key factors that customers choose us. No matter what production challenges our customers face or what special production needs they have, we will provide personalized solutions to ensure that we can solve the production problems for our customers and smoothly put them into production. By choosing HONEST, we are committed to continuously innovating in technology and meticulously controlling the process to provide customers with high-quality products and services to promote industry development and achieve a win-win situation jointly.  

 

By our extensive experience, we have not only achieved a leading position in the industry in terms of technology but have also won the recognition of customers for their quality. Our partners include several internationally renowned automotive and motor brands, and their affirmation is the best proof of the technical level of HONST. For inquiries regarding equipment solutions and quotations, please do not hesitate to contact us. We are ready to provide you with the necessary information and support