• Prototype manufacturer of electric motors & generators

MFG Services

Laser/EDM cut lams
Bonded cores
TIG welded cores
Phase coil insertion
Stator assembly
Rotor assembly
Precision rotor balance
Magnet assembly
Types of rotor assemblies
Carbon copy retention sleeves
Slotless/torroidal stators
Concentrated coil assembly
Encoder installation & alignment
Surge tester
Precision rotor balance

Magnet Retention High Speed Rotor Retention

When AC Induction machines are operated athigh speeds the rotor bars and end rings must be retained against mass movement from centrifugal forces causing imbalance.

IPM machines are sort of self retaining up to about 50 to 90 M/sec tip speeds.

SPM machines frequently must have magnet retention up to 1000 m/sec tip speed. The best method for this is the use of Carbon Composite sleeves fitted over the magnets.

We offer very high strength carbon sleeves and we assemble them in a pre-stressed condition to prevent any magnet lift-off at full speed. We can provide the sleeves, the tooling design and the assembly process as well or we can assemble your rotors.

We can provide high speed rotor designs, documentation, rotor assembly, balancing and spin testing.

Types of rotor assemblies
Carbon copy retention sleeves
Slotless/torroidal stators
Concentrated coil assembly
Encoder installation & alignment
Surge tester
Precision rotor balance

Complete electric machining testing services are available.

Electrical testing includes stator Hi-Pot and Purge testing:

Laser/EDM cut lams
Bonded cores
TIG welded cores
Phase coil insertion
Stator assembly
Rotor assembly
Precision rotor balance
Magnet assembly
Types of rotor assemblies
Carbon copy retention sleeves
Slotless/torroidal stators
Concentrated coil assembly
Encoder installation & alignment
Surge tester
Precision rotor balance

Stator Encapsulation Service Using Thermal Conductive Potting Materials

The magnet wire insulation and the VIP varnish used for many years in motor manufacturing has a very low thermal conductivity which make these layer between the conductors and the motor frame act like heat insulators. Any air gaps between the turns, the slot liners and the lamination core act also as insulators. The stator end turn space is also a very poor heat conductor and usually results as the hottest spot in the machine.

Significant improvements in machine continuous ratings can be achieved by eliminating the VIP treatment and replacing with complete vacuum encapsulation of the stator using thermal conductive epoxies or thermal plastics.

Hand potting
SEGWAY motor cut-a-way
Semi-automatic

We wind both layer wound coils for concentrated windings for single teeth assembly or sets of random wound phase coils.

We use our CNC Draw knife for cutting slot liners, insulators, and end boards.

We also use our fluidized bed table for insulating stator cores under 300 Volts.

We use our precision Stereolithographic 3D printer for creating coil bobbins, slot wedges, and insulated terminal blocks

About Motor Solver

Dedicated provider of most electric motor & generator prototypes, short run quantities electric machine components, (rotors & stators)
In our 2500 sq.-ft. shop we are equipped to provide most all the necessary core technologies for rotor and stator manufacturing plus final assembly .
We also perform final electrical testing and dynamometer performance testing.

Design Services

Electric Motor/Generator Design Documentation & Testing Services

Electric machine design services available for prototype motors including magnetic, mechanical, thermal and complete documentation services. Production costing and production process services available as well.

  • Phase coil design and winding instructions
  • Loss analysis including electrical, mechanical & magnetic
  • Thermal analysis and cooling design assistance
  • Machine selection trade studies
  • Production sourcing

Production Sourcing

Addition support services are provided by our staff for electric motors & generators

  1. After alpha and beta prototypes are designed, created, tested and approved production sourcing can be provided.
  2.  Production cost analysis is offered including tooling and equipment
  3. We also offer machine trade studies to determine the best electric machine type for your application. Reluctance, PM synchronous, or AC Induction
2D & 3D for mechanical layout and design documentation
2D & 3D for mechanical layout and design documentation
Software (by Infolytica) for electric machine analysis
Software (by CD-Adapco) for electric machine analysis
For system analysis
Software for voice coil & linear motor design
Many in-house developed spread sheet tools for special analysis

Electric Motor/Generator Design Documentation & Testing Services

Electric machine design services available for prototype motors including magnetic, mechanical, thermal and complete documentation services. Production costing and production process services available as well.

  • Phase coil design and winding instructions
  • Loss analysis including electrical, mechanical & magnetic
  • Thermal analysis and cooling design assistance
  • Machine selection trade studies
  • Production sourcing

Electric Motor/Generator Design Documentation & Testing Services

Electric machine design services available for prototype motors including magnetic, mechanical, thermal and complete documentation services. Production costing and production process services available as well.

  • Phase coil design and winding instructions
  • Loss analysis including electrical, mechanical & magnetic
  • Thermal analysis and cooling design assistance
  • Machine selection trade studies
  • Production sourcing

Production Sourcing

Addition support services are provided by our staff for electric motors & generators

  1. After alpha and beta prototypes are designed, created, tested and approved production sourcing can be provided.
  2.  Production cost analysis is offered including tooling and equipment
  3. We also offer machine trade studies to determine the best electric machine type for your application. Reluctance, PM synchronous, or AC Induction

Electric Motor/Generator Design Documentation & Testing Services

Electric machine design services available for prototype motors including magnetic, mechanical, thermal and complete documentation services. Production costing and production process services available as well.

  • Phase coil design and winding instructions
  • Loss analysis including electrical, mechanical & magnetic
  • Thermal analysis and cooling design assistance
  • Machine selection trade studies
  • Production sourcing

Production Sourcing

Addition support services are provided by our staff for electric motors & generators

  1. After alpha and beta prototypes are designed, created, tested and approved production sourcing can be provided.
  2.  Production cost analysis is offered including tooling and equipment
  3. We also offer machine trade studies to determine the best electric machine type for your application. Reluctance, PM synchronous, or AC Induction

Electric Motor/Generator Design Documentation & Testing Services

Electric machine design services available for prototype motors including magnetic, mechanical, thermal and complete documentation services. Production costing and production process services available as well.

  • Phase coil design and winding instructions
  • Loss analysis including electrical, mechanical & magnetic
  • Thermal analysis and cooling design assistance
  • Machine selection trade studies
  • Production sourcing

Other Services

Workshops

Custom prepared motor design workshops also are offered to companies with dedicated teaching material based upon company products.

Previous workshops:
Alstom
Valeo
Sonceboz
Magnaquench
NASA
WPAFB
ORNL
Oriental Motor Co
Maccon
Moog
Femsan