Iron core Material-Somaloy Unique magnetic properties High purity iron powder Electrically insulated surface. Result in.

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1 Iron core Material-Somaloy Unique magnetic properties High purity iron powder Electrically insulated surface 0,1mm Result in Inorganic insulation 3-D material with Iron particle Iron particle High magnetic saturation Low eddy current loss Sufficient strength

2 Somaloy vs. silicon steel lamination Somaloy materials have a distributed air-gap: => Lower permeability compared to laminations 1,8 1,6 B (T) 1,4 1,2 BH-curves 1,0 0,8 0,6 0,4 0,2 0,0 Somaloy 3P 0.35mm Si lamination H (A/m) The importance of permeability is application dependent

3 Somaloy vs. silicon steel lamination Total loss; DC+AC losses = area of hysteresis-curve Lamination constant sheet thickness DC High Frequency Somaloy small particle size Low DC loss High AC loss Medium DC loss Low AC loss

4 Somaloy vs. silicon steel lamination 0,65mm motor lamination Density 7,6g/cm 3 Measured on stamped and stacked ring sample Hysteresis curves 0.65mm laminate 2, 0 1, 0 H (ka/m) 0, , 0 B (T) DC 300Hz Somaloy 500 Hysteresis curves Somaloy 500-2,0 2,0 1,0 B (T) DC 300Hz Density 7,3g/cm 3 Measured on compacted and heat treated ring sample H (ka/m) 0, ,0-2,0

5 Comparison SMC losses vs. losses in laminates. In general: Somaloy vs. silicon steel lamination - Hysteresis losses: higher for SMC - Dynamic losses: lower for SMC - Hysteresis losses f - Dynamic losses f 2

6 Somaloy vs. silicon steel lamination Frequency/Iron loss SMC powder (Material) A B C D E Silicon steel lamination 0.5mm (50A400) 0.35mm (35JN360) 200HZ HZ HZ HZ KHZ KHZ KHZ KHZ Permeability Coercivity (Oe) Saturation flux(t)

7 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

8 Somaloy Main Features & Benefits 3D-magnetic properties Net 3D-shaping Smaller, Lighter and Cheaper Electric Motors

9 Somaloy Design Advantages Somaloy Redesign Criteria: Equal performance - Axially shorter - Significant Cu-savings - Tighter winding/less slot wall insulation Somaloy Redesign Criteria: Equal length aminated reference stator tooth - Improved performance - Cheaper magnets for equal performance - Tighter winding/less slot wall insulation

10 2,0 Application Areas DC Solenoid valve, Transformer Flux density (T) 1,5 1,0 0,5 Sintered P/M-Materials Motor Low Frequency sensors & actuators Stainless Steel AC Solenoid valve, HF Sensor Inverter, Switching elements Somaloy k 10k 100k 1M 10M Operating frequency (Hz)

11 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

12 Somaloy Target Applications Electric motors Sensors Actuators Reactors Ignition systems

13 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

14 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

15 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

16 Commercial Example : Ignition coil Ignition coil Pulse transformer Idea: Improved geometry, easier assembly Laminates have limited shaping possibilities Result: Somaloy design Circular smooth shape Magnetworld AG Philosophenweg Jena Tel.: +49(3641) Fax: +49(3641) info@magnet-world.de