In the fields of high-end equipment such as new energy vehicles and precision medical devices, coreless motors are favored for their advantages such as zero cogging and high response speed, but they are deterred by the high manufacturing cost. Why is the motor with a seemingly streamlined core structure more expensive than a traditional motor? This article will reveal the true veil of the high cost of coreless motors from the perspectives of technology, materials and production processes, and provide a practical cost reduction path.
Three core factors drive up manufacturing costs
The key to the soaring cost of coreless motors is first due to their reliance on high-performance permanent magnet materials. In order to make up for the magnetic circuit loss caused by the lack of an iron core, high magnetic energy product permanent magnets such as neodymium iron boron are required. The price of such materials is dozens of times that of ordinary ferrites, and the global supply chain fluctuates frequently, which directly drives up the cost of raw materials. Secondly, the complexity of the production process is far beyond that of traditional motors: since there is no iron core support, the winding coil needs to use precision winding technology and high-strength insulation materials to ensure structural stability; at the same time, the air gap accuracy of the coreless motor is required to reach the micron level, which puts extremely high standards on assembly equipment and testing technology, resulting in a significant increase in equipment procurement, commissioning and maintenance costs. In addition, due to the limited market size, R&D investment is difficult to be shared through mass production, and the R&D cost of a single product remains high, further exacerbating cost pressure.
Multi-dimensional cost reduction strategy breaks through the cost dilemma
To break the cost bottleneck of coreless motors, companies can work on three aspects: material substitution, process optimization and scale effect. In the field of materials, explore new permanent magnet materials such as samarium cobalt alloys, or develop composite magnetic circuit designs to reduce dependence on expensive rare earth materials; by optimizing the shape and magnetization direction of permanent magnets, reduce the amount of materials while ensuring performance. In terms of process improvement, introduce automated winding equipment and intelligent assembly systems to improve production efficiency and reduce manual errors; use 3D printing technology to manufacture complex winding structures and simplify the process flow. At the same time, enterprises should strengthen the coordination of the industrial chain, establish industrial alliances with upstream and downstream enterprises, and accelerate technology iteration and share costs by sharing R&D results and centralized procurement of materials.
Reduce costs and increase efficiency, and move towards large-scale production
Reducing the cost of coreless motors is not only the key to reducing costs and increasing efficiency for enterprises, but also an important opportunity to promote the upgrading of industry technology. Through cost optimization, coreless motors will be popularized and applied in more fields, accelerate the intelligent transformation of industries such as new energy vehicles and robots, and inject new momentum into intelligent manufacturing.
Phased implementation guide:
Technical research period: Jointly conduct material and process feasibility studies with scientific research institutions to evaluate potential cost reduction solutions;
Pilot verification period: Select key process links for small-batch trial production and collect data to optimize solutions;
Scale promotion period: Establish long-term cooperation with supply chain partners to reduce marginal costs through mass production;
Continuous optimization period: Establish a cost monitoring system and dynamically adjust process parameters and procurement strategies.
The high cost of coreless motors is not insurmountable. Through technological innovation, process optimization and industrial collaboration, enterprises can fully achieve a balance between performance and cost. If you are looking for a breakthrough in cost reduction, you might as well start with the strategies provided in this article, or contact a professional organization to obtain customized solutions and embark on a new journey of efficient and low-cost motor manufacturing.