Amorphous Laminated Cores High-performance motor cores

Background of Amorphous Alloy Utilization

As efforts toward a carbon-neutral society accelerate, improving motor efficiency has become more critical than ever.
A key factor in this advancement is the motor core material itself. Iron-based amorphous alloy ribbons have drawn attention for their ability to reduce core loss to about one-tenth compared to conventional electrical steel sheets.

This feature is particularly advantageous in high-speed rotation, enabling the design of compact, high-output motors that significantly contribute to energy savings.
However, due to the extremely thin and hard nature of amorphous materials, conventional press processing technologies have faced challenges in achieving mass production.

Development of Amorphous Laminated Core

Our company has focused on developing die technology to enable mass production of amorphous cores and has acquired patents related to the stamping and lamination of amorphous alloys.

Challenge:

Due to the nature of amorphous alloys, they place a significant burden on tooling, making them unsuitable for general mass production methods.

Defects Occur After 100 Shots

Solution

We developed a specialized punch and pursued automation of the lamination process.
As a result, we obtained patents covering both the stamping and lamination technologies.

No Defects Even After 800,000 Shots!

picture of Stamped Tooth Shapes — Stamped Tooth Shapes
(Thickness:0.025㎜)

picture of KAGURA — KAGURA (Laminated Split Cores)
(Outer diameter:φ130㎜)

picture of Original Core — Original Core
(Outer diameter:φ30㎜)

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Application to Motors and Evaluation Results

In 2022, to promote the market expansion of amorphous laminated core technology, we established Next Core Technologies Co., Ltd. *and developed a brushless DC motor to demonstrate the core's performance.
The motor achieved a world-class efficiency of 98% in the 5kW class - an improvement of 5-10% over motors of comparable output - and a power density of 1.2kW/kg.

(*Next Core Technologies Co., Ltd. is a joint venture of three companies including ours.)

Maximum efficiency≧98%:Only mechanical los:ses ot ~he torque meter were corrected. No correctio11 for mecl,anfca1 losses (bearing losses).

Source:https://www.nextcore.jp/

Realizing Carbon Neutrality

Creating Environmentally Friendly Products

We believe that high-efficiency motors utilizing amorphous laminated cores can significantly contribute to reducing global energy consumption.
Our company is seeking partner companies to collaboratively develop the next generation of high-performance motors based on amorphous laminated core technology.

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