Axial Flux Motor Stator Core for Robotics & Servo Joint Actuators Custom Wound Core

Key Technical Advantages for Robotic & Servo Applications

• Ultra-Compact Axial Envelope & High Torque Density: The disc-shaped axial flux topology shortens the magnetic flux path parallel to the motor shaft, drastically reducing actuator axial length and total joint weight compared to conventional cylindrical radial flux stators.
• Ultra-Low Iron Loss at High Electrical Frequencies: Utilizing thin-gauge non-oriented electrical steel (0.10 mm to 0.35 mm) suppresses high-frequency eddy current losses and minimizes joint motor heat build-up during continuous high-speed positioning.
• Optimized Radial Slot Geometry for High Slot Fill Factor: CNC laser-formed teeth provide burr-free edges and customizable radial slot shapes, allowing dense copper wire winding and maximum magnetic flux concentration.
• Zero Tooling Investment for Rapid Prototyping: Modify slot count, skew angle, inner diameter (ID), and outer diameter (OD) directly through CNC laser programming without manufacturing costly stamping dies.

Technical Specifications & Parameter Matrix

Robotics & Precision Automation Applications

Our custom wound axial flux cores are engineered to meet stringent thermal, dimensional, and magnetic demands across specialized motion control fields:

• Collaborative Robot (Cobot) Joints: Ultra-thin profile integrates seamlessly with harmonic or cycloidal speed reducers.
• Humanoid Robot Actuators: Maximizes torque-to-weight ratio for hip, knee, ankle, and shoulder rotary joints.
• Direct-Drive & Frameless Servo Motors: Eliminates backlash and provides smooth low-speed torque with minimal cogging torque.
• AGV / AMR Wheel Hub Drives: Delivers high starting torque in narrow wheel hub compartments.

Customization & OEM/ODM Capability (Built to Your Drawing)

We specialize in rapid custom manufacturing tailored to your exact motor electromagnetic design:

1. Design Input: Send your 2D/3D drawing (DWG, DXF, STEP) or CAD model with OD, ID, slot geometry, and stack height.
2. DFM Analysis: Our engineering team conducts design-for-manufacturability analysis on strip winding, laser slot parameters, and tolerances.
3. Rapid Prototyping: Laser-cut samples produced within 7–12 working days without stamping die lead times.
4. Validation: Comprehensive CMM dimensional inspection and core loss testing before batch delivery.

Precision Manufacturing & Quality Control

Shunge Steel ensures exceptional magnetic and mechanical reliability through stringent in-house quality control:

• Tension-Controlled Continuous Winding: Eliminates inter-layer delamination and ensures high stacking factor.
• Laser Edge Integrity Inspection: Continuous laser parameter monitoring prevents micro-shorting between laminations, preserving electrical insulation.
• Stress-Relief Annealing: Controlled atmosphere annealing relieves winding and cutting stresses, fully restoring optimal magnetic permeability.
• Full Dimensional & Magnetic Verification: Coordinate Measuring Machine (CMM) inspection for OD/ID concentricity, slot profile accuracy, and core loss testing.

Packaging & Global Logistics Protection

Cores are packaged to ensure zero rust, geometry protection, and slot edge preservation during long-distance international transit:

• Anti-Rust Vacuum Sealing: Cores are coated with eco-friendly anti-corrosion oil and vacuum-sealed in VCI anti-rust barrier bags.
• Shockproof Custom Foam: Encased in high-density custom-cut EPE foam inserts to prevent collision.
• Export Standard Crates: Packed in heavy-duty corrugated cartons or fumigation-free solid wooden crates for air and ocean freight.

Frequently Asked Questions (FAQ)

Q1: Why choose an axial flux stator core over a radial flux core for robot joint motors?
A: Axial flux motors deliver significantly higher torque density and a much shorter axial length (pancake form factor). This allows the motor to be integrated directly inside compact robot joint actuators without adding unnecessary overhang or inertia.

Q2: Can you customize the slot number and dimensions according to our motor CAD drawing?
A: Yes. All our axial flux stator cores are 100% custom-built. Because slots are formed via high-precision CNC laser cutting rather than progressive stamping dies, we can produce any custom slot geometry, diameter, or skew angle directly from your STEP or DWG files.

Q3: What electrical steel thickness is recommended for high-speed robotic servo actuators?
A: For high operating frequencies (e.g., above 400 Hz), we recommend thin-gauge electrical steel (0.10 mm to 0.20 mm) to minimize high-frequency eddy current losses and thermal rise. For standard frequencies, 0.27 mm or 0.35 mm is highly cost-effective.

Q4: How do you prevent inter-layer short circuits during laser slot cutting?
A: We utilize optimized high-speed laser cutting optics and inert assist gas parameters to ensure smooth, burr-free edges. Furthermore, post-process deburring and insulating coatings maintain layer-to-layer insulation resistance.

Q5: What is the typical lead time for prototype samples?
A: Since no stamping tooling is required, prototype stator cores are typically manufactured and dispatched within 7 to 12 working days upon CAD drawing confirmation.