Proper Design
Designing the most efficient motor is a key aspect of weight reduction, and since most motors are designed for widespread use, the right motor for a specific application is often larger than needed. To overcome this challenge, it is important to find a motor manufacturing company willing to make changes in a semi-custom manner, from motor windings and magnetics to frame dimensions. To ensure you have the correct windings, you need to know the motor's specifications so that you can maintain the precise torque and speed required for your application. In addition to adjusting the windings, manufacturers can also change the magnetic design of the motor based on changes in magnetic permeability. Proper placement of rare earth magnets between the rotor and stator can help increase the overall torque of the motor.
New Manufacturing Process
Manufacturers are able to continuously upgrade their equipment to produce motor components with higher tolerances, eliminating the thick walls and dense areas that once served as safety margins against breakage. Because each component is redesigned and manufactured using the latest technology, weight can be saved in multiple places that contain magnetic components, including insulation and coatings, frames, and motor shafts.
Material Selection
Material selection has an overall impact on motor operation, efficiency and weight, which is why so many manufacturers use aluminum frames instead of stainless steel, to take the most obvious example. Manufacturers have continued to experiment with materials with electromagnetic and insulating properties, and manufacturers are using a variety of different composite materials as well as lighter metals that offer lightweight alternatives to steel components. For installation purposes, a variety of reinforced plastics, polymers and resins are available, depending on the user's specific requirements for the final motor. As motor designers continue to experiment and research alternative components, including less dense coatings and resins for sealing purposes, they are breathing new life into the production process, which often affects the weight of the motor. In addition, manufacturers also offer frameless motors, which contribute to the weight of the motor by completely eliminating the frame.
