The No Cogging Effect of Coreless Motors

In modern precision and high-performance equipment, hollow-cup motors occupy an important position thanks to their light weight, high efficiency and fast response time. The "No cogging effect" is one of its core competencies, and it is this effect that makes it stand out in many demanding scenarios. So what exactly is the "No cogging effect" and what is its unique impact on motor performance?

 

 

First of all, we should know that the cogging force is usually caused by the interaction between the customized iron core and the rotor magnetic field, which can trigger torque fluctuation in transmission motors, leading to unstable operation, high vibration, noise and so on. In contrast, Coreless motors fundamentally eliminate cogging force due to the ironless core design idea, achieving smoother and more stable operation.

 

We can use a simple analogy to describe, you are riding fast on a highway, if the highway is very bumpy and uneven, you will feel the whole car is vibrating, and it affects the riding experience, and the No cogging effecteffect, that is to let you ride on a very smooth highway, then you will ride very fast and smooth.

 

 

Coreless design: Hollow-cup motors utilize a coreless rotor design, which reduces eddy-current and hysteresis losses caused by the core.

 

High precision winding process

1. Precision winding wiring: through advanced automated precision winding machine, the coils are precisely and evenly arranged on the winding skeleton.
2. Fine wire multi-layer structure: multi-layer winding design using smaller diameter wires, thus increasing the winding density and reducing the magnetic interference between the wires.
3. Winding shape optimization: by optimizing the coil geometry (e.g. flat design), the conductive cross-sectional area of the winding is increased, thus reducing resistance and improving efficiency.

These three ways above, through different winding process optimization, and then enhance the No cogging effect of Coreless motor.

learn more: Winding technology is the core barrier of hollow cup motor

 

Optimized magnetic field structure:

1. Optimized magnetic circuit design: uniform distribution of magnetic field, reasonable design of the magnet gap, the use of multi-pole magnetic circuit design
2. Use of high-performance materials: high-performance permanent magnet materials such as neodymium-iron-boron (NdFeB), and the use of lightweight, high conductivity oxygen-free copper or silver-plated copper wire
3. Design of the adjustment air gap: increasing air gap uniformity and controlling air gap lengths

By optimizing the magnetic field structure in the above three ways, the motor can ensure the smoothness of the magnetic field during operation and further reduce mechanical vibration and noise.

 

 

1. Smooth running performance

Due to the elimination of the cogging force, the Coreless motor has a more stable torque output, especially at low speeds, and even maintains precise control without all knowing.

 

2. Greater efficiency

The cogging-free design means that hysteresis and eddy current losses are reduced, increasing the efficiency of hollow-cup motors (up to even 95%) and extending the range of the device.

 

3. Lower noise and vibration

The motor will be quieter and the vibration will be dramatically reduced during operation without the interference of the cogging force

 

4. Higher dynamic response

The combination of a lightweight coreless construction and the No cogging effect allows hollow-cup motors to start and stop quickly.

 

 

Thanks to the cogging-free effect, hollow-cup motors perform particularly well in many areas:

 

Medical: insulin pumps, surgical robots, bionic hands and feet, dental handheld disclosures, centrifuges/blenders, surgical bone drills

 

Aerospace: long-haul aircraft, spacecraft, unmanned aerial vehicles, drones, civil aviation technology

 

Robotics: agricultural robots, service robots, inspection robots, bionic robots, remote-controlled robots

 

Electric handheld devices: tattoo machines, electric toothbrushes, power drills, power saws, hair dryers

 

Industrial automation: conveyor belts, semiconductor manufacturing, printing industry automation, textile industry automation

 

 

The following common problems are likely to be faced while shopping for the right Coreless motor manufacturer:

 

1. Product quality varies

There are many manufacturers around the world, each claiming that their motors are superior in performance, but in actual use they may have short life, unstable operation, low efficiency and other problems.

 

When choosing a manufacturer, customers need to identify whether it has advanced production processes and strict quality control systems

 

2. Lack of technical support

In the process of research and development and use, manufacturers are required to provide technical guidance or customization services, but some manufacturers' technical teams are not experienced enough, resulting in the inability to provide the best customized solutions, or slow response in dealing with problems

 

At this point in time, when choosing, you should choose manufacturers with years of experience in the industry, and has a team of engineers

 

3. Long lead times

Some manufacturers may not be able to deliver on time due to lack of production efficiency or insufficient material preparation, which delays the customer's project schedule.

 

This requires customers to focus on the manufacturer's production strength and factory size when choosing a manufacturer, both of which determine its production efficiency

 

4. Poor value for money

High-performance motors tend to be more expensive, but the quality and performance of lower-priced products may not meet demand

 

This requires that when choosing a manufacturer, customers need to make sure that they find a source manufacturer, not a third-party operator, or even a fourth-party operator, which will directly determine the price/performance ratio of their product

 

5. Insufficient industry certification

For some high standard industries (e.g. medical, automotive, aerospace) motors are required to pass specific certifications (e.g. ISO, CE, etc.), but many manufacturers are not qualified for these.

 

6. Inadequate after-sales service

For customized motors, failures or problems may occur in actual applications, but the after-sales service of some manufacturers is not timely or professional, which will lead to the loss of a lot of market and reputation of the customer

 

Regarding the above points, which are the most common and easily encountered problems, it is necessary for customers to have an astute insight and comprehensive examination to ensure that the most suitable manufacturer of Coreless motor is selected to provide efficient and reliable power support for your project and help you succeed.

 

For customized Coreless motor, VSD Micromotors, with more than a decade of industry experience, has been equipped with more than 10,000 square meters of modern factory building with 30+ senior R&D staff, 500+ frontline employees, and 40+ efficient assembly lines. It is also equipped with 300+ sets of advanced automation equipment to ensure efficient production and consistent quality of products.

 

In order to provide a more accurate service, we have a specialized sample processing workshop, as well as a number of functional departments, such as purchasing department, quality inspection department, research and development department, to ensure that each link can be accurately controlled to meet the various needs of customers.

 

At present, VSD has obtained ISO, CE, IATF and other international quality management system certificates, and continues to invest nearly a million dollars a year in technology research and development and innovation, and strives to always maintain the forefront of the industry in the field of motor technology.

 

We focus on providing highly customized design solutions and offer complete OEM and ODM services. Currently, we have provided customized services to more than 90% of our customers, and have established long-term and stable relationships with internationally renowned companies, including Panasonic, Philips, etc., which have won us extensive trust and high praise.

 

Whether it is innovative design for specific industry needs or quality control for mass production, VSD can provide you with the most competitive solutions to help your project succeed. Meanwhile, no matter what you need at the moment, you can leave us a message, leave your contact information, we will get in touch with you within 24 hours, I believe that in the near future, we will be the most long-term and stable partners.

 

For more information about VSD, please click: About Us, or feel free to visit our factory.