• 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
Somaloy® vs. silicon steel lamination
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
Somaloy® vs. silicon steel lamination
• 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
Somaloy® vs. silicon steel lamination
In general:
Somaloy® vs. silicon steel lamination
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
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
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