Smc iron core

• Electrically insulated surface

3-D material with

Iron core Material-Somaloy

• High purity iron powder

Unique magnetic properties

• High magnetic saturation• Low eddy current loss • Sufficient strength

Result in

0,1mm

Iron particle

Iron particle

Inorganic insulation

Somaloy materials have a distributed air-gap:=> Lower permeability compared to laminations

The importance of permeability is application dependent

Somaloy® vs. silicon steel lamination

BH-curves

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

1,8

0 2000 4000 6000 8000 10000 12000

H (A/m)

B (T)

Somaloy 3P

0.35mm Si lamination

Laminationconstantsheetthickness

Somaloysmallparticlesize

Total loss; DC+AC losses = area of hysteresis-curve

Low DC loss

Medium DC loss

High AC loss

Low AC loss

DC High Frequency


Hysteresis curves

Somaloy 500

-2,0

-1,0

0,0

1,0

2,0

-20 -15 -10 -5 0 5 10 15 2

H (kA/m)

B (T)

DC

300Hz

Hysteresis curves

0.65mm laminate

-2,0

-

2

0

1

1

,

,

,

,

0

0

0

0

-20 -15 -10 -5 0 5 10 15 2

H (kA/m)

B (T)

DC

300Hz


• 0,65mm motor lamination

• Density 7,6g/cm3

• Measured on stamped and

stacked ring sample

• Somaloy® 500

• Density 7,3g/cm3

• Measured on compactedand heat treated ring sample

Comparison SMC losses vs. losses in laminates.

- Hysteresis losses ∝ f

- Dynamic losses ∝ f2

- Hysteresis losses:higher for SMC

- Dynamic losses:lower for SMC


In general:


2.01.3 1.51 1.66 1.71 1.4 1.8Saturation flux(T)

1.14.8 3.2 2.8 2.7 3.1 1.5Coercivity (Oe)

2000300 500 700 780 472 1800Permeability

14062126875.41097 882.9 944.5 931.46KHZ

717.71201491.9604.1 499.5 524 513.14KHZ

233344.5210.2235.8 201.3 208 202.52KHZ

80.6119.4100.7104.4 90.7 88.25 83.571KHZ

62.1857786.9 74.7 67.1 63.14800HZ

36.453.35762.9 54.5 48 47.2600HZ

19.728.436.441.7 35.3 30.35 30.1400HZ

7.610.11717.9 16.9 14.35 13.97200HZ

0.35mm

(35JN360)

0.5mm

(50A400)A B C D E

Silicon steel laminationSMC powder (Material)

Frequency/Iron loss

ǳǳǳǳ

Somaloy® Part Manufacturing –

The P/M - Process

Benefits:

� Net shape

� Low cost

� Good tolerances (IT 7-11)

� Smooth surfaces

� Low material waste (< 5%)

Globally established industry

3D-magnetic properties Net 3D-shaping

� Smaller, Lighter and Cheaper Electric Motors

Somaloy® – Main Features & Benefits

Somaloy® Design Advantages

Laminated reference stator tooth

Somaloy® Redesign Criteria: Equal performance

- Axially shorter

- Significant Cu-savings

- Tighter winding/less slot wallinsulation

Somaloy® Redesign Criteria: Equal length

- Improved performance

- Cheaper magnets for equal performance

- Tighter winding/less slot wall insulation

1 10 100 1k 10k 100k 1M 10M

0.0

0,5

1,0

1,5

2,0

Somaloy®

Operating frequency (Hz)

Flu

x d

en

sit

y (

T)

Stainless Steel

Sintered

P/M-Materials

DC Solenoid valve, Transformer

AC Solenoid valve, HF Sensor

Inverter, Switching

elements

Low Frequency

sensors &

actuators

Motor

Application Areas

Somaloy® Target Motor Applications and Benefits

Motor Types

Brushless DCBrushed DCLinearTFM/Claw PoleUniversal

Benefit Examples

Compact designCu-wire reductionCheaper magnetsSimpler windingHigh torque densityElimination of gearboxPart number reduction

Easier assemblyIntegrated features

More efficient use of magnets

Somaloy® Target Applications

• Electric motors

• Sensors

• Actuators

• Reactors

• Ignition systems

Commercial Example : Servo Motor

Courtesy Phase Motion Control, Italy

Servo motors Ultrac TW (left) and T (right)

Brushless Servo Motor - Phase Motion Control S.r.l

Result: Somaloy® designNovel multipolar designSize and weight reduction by 1/3Exceptional high torque density

Idea: Reduce motor size

Original: Laminated design

Commercial Example : ABS Pump Motor

Courtesy Aisin Seiki Co., Ltd, Japan

Result: Somaloy® 3D designDrastic weight reductionMore compact designFlux concentration

Idea: Size and weight reduction

BDC Pump Motor – Aisin Seiki Co., Ltd

Commercial Example : Linear Compressor

Linear Compressor – Twinbird Corporation

Result: Somaloy® design 5 partsEasier assembly and cheaperSimilar performanceReduced weight and nosie

Courtesy Twinbird Corporation, Japan

Idea: Reduced assembly work(Laminated design 1300 parts)

Free Piston Stirling Cooler

Commercial Example : Ignition coil

Result: Somaloy® designCircular smooth shape

Idea: Improved geometry, easier assemblyLaminates have limited shapingpossibilities

Ignition coil – Pulse transformer

Magnetworld AG Philosophenweg 40 07743 Jena Tel.: +49(3641) 6396920 Fax: +49(3641) 6396921 Magnetworld AG Philosophenweg 40 07743 Jena Tel.: +49(3641) 6396920 Fax: +49(3641) 6396921 email: [email protected] www.magnet-world.de

Magnetworld AG Philosophenweg 40 07743 Jena Tel.: +49(3641) 6396920 Fax: +49(3641) 6396921 email: [email protected] www.magnet-world.de

Smc iron core

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