Why Your BLDC Stator Runs Hotter Than the Rotor: Understanding and Managing Heat in Brushless DC Motors
You felt the stator on your brushless DC motor. Hot. The rotor? Warm at best. You are not imagining…
TCO of Self-Bonding vs. Welding for Motor Cores: Unpacking the True Costs and Benefits
Every engineering leader faces the same tough call at some point. How should we assemble our motor core laminations…
The Critical Link: How Slit Coil Quality Impacts Transformer Lamination Consistency and Performance
Table of Contents Introduction: Why slit coil quality makes or breaks a transformer core What defines “slit coil quality”…
Optimizing Oil-Immersed Transformer Lamination Design for Significant Noise Reduction
Table of contents Introduction I design and troubleshoot oil-immersed transformers for a living. Over the years I’ve learned one…
Can Self-Bonding Electrical Steel Reduce Motor Core Losses and Noise?
Short answer. Yes. In many motors self-bonding electrical steel can cut core losses and lower noise. In this guide…
Case Study: Hairpin Stator Improves Slot Fill and Lowers Copper Loss
Table of Contents Case Study: Hairpin Stator Improves Slot Fill and Lowers Copper Loss What problem do round wire…
A Practical Guide to Designing Motor Cores for Automated Winding
You’ve done it. You designed the perfect electric motor on your computer. It’s powerful and efficient. But then, the…
The Silent Culprit: How Lamination Stack Quality Dictates NVH in Passenger Vehicles
Have you ever ridden in an electric car and noticed that high-pitched whine? It’s a sound that can get…
What Are Motor Lamination Stacks and Why Do They Matter for Performance?
Every design engineer faces the critical challenge of maximizing electric motor efficiency while managing complexity and production costs. If…
How Tiny Changes in Motor Design Create Huge Results: Your Guide to Airgaps, Teeth, and Ribs
Have you ever tried to build something complex? Maybe a model airplane or a computer? You know that one…
NVH Prediction Guide: Analyzing Stator Slotting and Rotor Magnet Forces in E-Motors
Have you ever driven in an electric vehicle (EV) and heard that high-pitched whine? It’s a sound that can…
Variation Simulation: Mastering the Link Between Stack Height and Magnet Airgap Alignment
Have you ever built something where all the parts seemed perfect, but the final product was a dud? It…
