Iron core Material-Somaloy
Unique magnetic properties
•
•
High purity iron powder
Electrically insulated surface
Inorganic
insulation
Iron
particle
Result in
3-D material with
•
•
•
High magnetic saturation
Low eddy current loss
Sufficient strength
Iron
particle
0,1mm
Somaloy® vs. silicon steel lamination
Somaloy materials have a distributed air-gap:
=> Lower permeability compared to laminations
1,8
B (T)
1,6
1,4
BH-curves
1,2
1,0
0,8
Somaloy 3P
0,6
0.35mm Si lamination
0,4
0,2
H (A/m)
0,0
0
2000
4000
6000
8000
10000
The importance of permeability is application dependent
12000
Somaloy® vs. silicon steel lamination
Total loss; DC+AC losses = area of hysteresis-curve
DC
High Frequency
Lamination
constant
sheet
thickness
Low DC loss
High AC loss
Medium DC loss
Low AC loss
Somaloy
small
particle
size
Somaloy® vs. silicon steel lamination
2,0
Hysteresis curves
0.65mm laminate
• 0,65mm motor lamination
• Density 7,6g/cm3
• Measured on stamped and
stacked ring sample
B (T)
DC
300Hz
1,0
H (kA/m)
0,0
-20
-15
-10
-5
0
10
15
2
-1,0
-2,0
2,0
Hysteresis curves
Somaloy 500
• Somaloy® 500
• Density 7,3g/cm3
• Measured on compacted
and heat treated ring sample
5
B (T)
DC
300Hz
1,0
H (kA/m)
0,0
-20
-15
-10
-5
0
-1,0
-2,0
5
10
15
2
Somaloy® vs. silicon steel lamination
Comparison SMC losses vs. losses in laminates.
In general:
- Hysteresis losses:
higher for SMC
- Dynamic losses:
lower for SMC
- Hysteresis losses ∝ f
- Dynamic losses ∝ f2
Somaloy® vs. silicon steel lamination
SMC powder (Material)
Silicon steel lamination
Frequency/Iron loss
A
B
C
D
E
0.5mm
(50A400)
0.35mm
(35JN360)
200HZ
17.9
16.9
14.35
13.97
17
10.1
7.6
400HZ
41.7
35.3
30.35
30.1
36.4
28.4
19.7
600HZ
62.9
54.5
48
47.2
57
53.3
36.4
800HZ
86.9
74.7
67.1
63.14
77
85
62.1
1KHZ
104.4
90.7
88.25
83.57
100.7
119.4
80.6
2KHZ
235.8
201.3
208
202.5
210.2
344.5
233
4KHZ
604.1
499.5
524
513.1
491.9
1201
717.7
6KHZ
1097
882.9
944.5
931.4
875.4
2126
1406
Permeability
300
500
700
780
472
1800
2000
Coercivity (Oe)
4.8
3.2
2.8
2.7
3.1
1.5
1.1
Saturation flux(T)
1.3
1.51
1.66
1.71
1.4
1.8
2.0
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
Somaloy® – Main Features & Benefits
3D-magnetic properties
Net 3D-shaping
Smaller, Lighter and Cheaper Electric Motors
Somaloy® Design Advantages
Laminated reference stator tooth
Somaloy® Redesign Criteria:
Equal performance
- Axially shorter
- Significant Cu-savings
- Tighter winding/less slot wall
insulation
Somaloy® Redesign Criteria:
Equal length
- Improved performance
- Cheaper magnets for equal
performance
- Tighter winding/less slot wall
insulation
Application Areas
2,0
Flux density (T)
DC Solenoid valve,
Transformer
AC Solenoid valve,
HF Sensor
1,5
Sintered
P/M-Materials
Motor
1,0
Low Frequency
sensors &
actuators
0,5
Somaloy®
In
v
el er
em te
en r, S
ts wi
Stainless
tc
hi
Steel
ng
0.0
1
10
100
1k
10k
100k
1M
10M
Operating frequency (Hz)
Somaloy® Target Motor Applications and
Benefits
Motor Types
Brushless DC
Brushed DC
Linear
TFM/Claw Pole
Universal
Benefit Examples
Compact design
Cu-wire reduction
Cheaper magnets
Simpler winding
High torque density
Elimination of gearbox
Part number reduction
Easier assembly
Integrated features
More efficient use of magnets
Somaloy® Target Applications
• Electric motors
• Sensors
• Actuators
• Reactors
• Ignition systems
Commercial Example : Servo Motor
Brushless Servo Motor - Phase Motion Control S.r.l
Original: Laminated design
Idea:
Reduce motor size
Result: Somaloy® design
Novel multipolar design
Size and weight reduction by 1/3
Exceptional high torque density
Servo motors Ultrac TW (left) and T (right)
Courtesy Phase Motion Control, Italy
Commercial Example : ABS Pump Motor
BDC Pump Motor – Aisin Seiki Co., Ltd
Idea:
Size and weight reduction
Result: Somaloy® 3D design
Drastic weight reduction
More compact design
Flux concentration
Courtesy Aisin Seiki Co., Ltd, Japan
Commercial Example : Linear Compressor
Linear Compressor – Twinbird Corporation
Free Piston Stirling Cooler
Idea:
Reduced assembly work
(Laminated design 1300 parts)
Result: Somaloy® design 5 parts
Easier assembly and cheaper
Similar performance
Reduced weight and nosie
Courtesy Twinbird Corporation, Japan
Commercial Example : Ignition coil
Ignition coil – Pulse transformer
Idea:
Improved geometry, easier assembly
Laminates have limited shaping
possibilities
Result: Somaloy® design
Circular smooth shape
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email: info@magnet-world.de www.magnet-world.de