A compressor manufacturer faced a pressing challenge: how to replace their bulky, noisy induction motors. The goal was to stop using the traditional flanged motors mounted externally on the compressors and instead embed a newly designed motor directly within the system. Enabling a more compact and cost-efficient design.
The solution came in the form of a custom frameless motor developed by Magnetic Innovations. Using our standard MI-F 110 series as the foundation, we delivered a high-torque, direct-drive motor tailored to their unique specifications.
Reduced System
Size and Weight
Direct PCB
Connection
High Torque
Output
Efficient
Energy Use
Project Approach: Turning Challenges into Solutions
The customer needed a compact, high-torque motor for their gas pump application. The existing induction motors used in the compressor design were limited in efficiency and required external mounting, adding complexity and size to the overall system.
Leveraging our MI-F 110 series as a starting point, we collaborated closely to design a custom frameless motor that integrates seamlessly with their system.
To meet their requirements, we scaled the motor down from a standard 25 mm stack height to a slimmer 20 mm stack, optimizing it for the gas pump’s size and performance requirements.
We also redesigned the rotor and optimized the winding configurations to meet the application’s specific torque and efficiency needs.
The custom frameless motor design incorporated insulation displacement (IDC) connectors for direct PCB connection, eliminating unnecessary wiring and simplifying assembly.
Project Results Torque Motor 110-20
The end result was a compact, lightweight customized frameless motor capable of delivering the required torque without the need for a transmission stage. The customized motor could be mounted inside the compressor housing, unlike the previous external induction motor setup.
Other key results were:
- Compactness and Weight Reduction: The smaller stack height and compact design significantly reduced the compressor’s overall size and weight.
- Enhanced Efficiency: Our direct-drive motor design offers higher efficiency compared to the previous induction motor setup.
- Noise Reduction: With optimized magnetic configurations and low cogging, the new motor operates more quietly, enhancing user experience.
- Seamless Integration: The motor’s direct PCB connection simplifies assembly, reduces cabling requirements, and improves reliability.
Specifications Custom Frameless Motor
Magnetic Innovations has successfully developed a compact, frameless outrunner motor tailored for our customer seeking a smaller, quieter, and more efficient alternative to traditional induction motors used in gass compressors.
The final custom product was delivered as a stator and rotor assembly, providing the customer with flexibility to integrate the motor into their gas pump.
This customized frameless motor not only met the client’s technical and operational requirements but also set a new benchmark in simplifying motor-to-system connections for similar applications.
If you face similar challenges in your applications, we’re here to help engineer the ideal solution for you.
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