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Hint: Choose your laminate thickness wisely.
How do you get the best performance out of your high-speed motor?
When thinner is better (and when it’s not)
E-mobility vehicles have different motor needs. Enhanced power density and torque density are critical. It is understood that using a thinner lamination can reduce AC losses in high-frequency operation of motors -- however, going too thin can have side effects.
Too thick
Too Thin
Using a stack with thick laminations outside of a reasonable frequency range can cause side effects detrimental to overall motor performance.
Eddy current loss generally increases as lamination thickness increases
However, using thin laminations when not necessary drives up the cost of stator and rotor stacks, often without much improvement in motor performance.
More processing is required and material stresses, handling, and stacking factor are challenging
AC losses in high-frequency operation of motors
Choose your Hiperco lamination thickness
0.35mm
0.25mm
0.15mm
0.10mm
Core loss (W/kg@1.5T)
Frequency (Hz)
60 Hz
400 Hz
1000 Hz
Frequency (Hz)
10
100
60 Hz
400 Hz
1000 Hz
Core loss (W/kg@1.5T)
2
10
50
6
18
70
8
30
85
12
45
150
View All
Core loss (W/kg@1.5T)
Frequency (Hz)
60 Hz
400 Hz
1000 Hz
Frequency (Hz)
10
100
60 Hz
400 Hz
1000 Hz
Core loss (W/kg@1.5T)
2
10
50
6
18
70
8
30
85
12
45
150
A good starting point for finding the optimal lamination thickness for your high-speed motor applications is to look at the crossover point where eddy current losses dominate overall losses. This occurs at higher frequency for thinner laminations. To find the best laminate thickness for you, start by choosing the frequency that matches your application.
Find the best lamination thickness for you
While this overview provides a good starting point, the optimal choice of lamination thickness and stack requires careful consideration. Further, through expert processing we can modify the optimal frequency and maximize stack performance for thin laminations to suit your application.
Hiperco thickness selection by frequency – a starting point
Choose your Hiperco lamination thickness
0.35mm
0.25mm
0.15mm
0.10mm
0.05mm
Frequency (Hz)
0%
50%
150 Hz
800 Hz
1800 Hz
% of loss contribution
100%
300 Hz
<150 Hz
150-300 Hz
300-800 Hz
800-1800 Hz
>1800 Hz
Modifying core loss
For low speed, high frequency range applications running at low frequency 0.35mm thick Hiperco strip is a popular choice. Stacks using this thickness typically perform well up to 150 Hz.
<150 Hz
Thinner 0.25mm Hiperco works effectively up to 300 Hz.
150-300 Hz
Our 0.15mm thick Hiperco covers the range from 300 Hz up to 800 Hz.
300-800 Hz
And from 800 Hz to 1800 Hz 0.1mm thick laminations are typically preferred.
800-1800 Hz
For applications above 1800 Hz materials thinner than 0.10mm are typically needed.
>1800 Hz
The magnetic and mechanical properties of our alloys and stacks can be modified by varying process parameters to improve core loss behavior. Through expert processing, we can modify the range of optimal operational frequency for a lamination thickness.
Modifying core loss
Hysteresis losses
Eddy current losses
Get the optimal laminate thickness for your high-motor needs.
Modifying core loss
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Talk to an application expert
Sample modification of 0.15mm
Read more about optimizing motor torque and power density
Download high frequency flyer
Core loss (W/kg@1.5T)
Frequency (Hz)
60 Hz
400 Hz
1000 Hz
Frequency (Hz)
10
100
60 Hz
400 Hz
1000 Hz
Core loss (W/kg@1.5T)