VERTICALLY INTEGRATED MANUFACTURING (VMI) CAPABILITIES

As a leader in electric motor manufacturing, CMI takes a vertically integrated approach to product development. This means that we offer all the manufacturing services a project requires under one roof. From development to manufacturing through Final Assembly, Test and Ship; we streamline your motion and control solution and offer the following benefits:

• Uncompromised Performance
• Reduced manufacturing costs
• Best in Class Lead Times
• Superior Quality and Reliability

In addition to standard motor manufacturing of lamination stacks/winding and rotor assembly, our manufacturing services include injection over-molding, Surface Mount Population of PCB’s precision machining, Vacuum Pressure Impregnation (VPI) and parylene coatings.

STATOR MANUFACTURING

In an electric motor, the stator is the core of the motor and is composed of individual silicon steel laminations that are electrically isolated. In order to create a “lam stack”, adhesives or welding processes are utilized. CMI manufactures the individual laminations with laser cutting (typically for prototypes) or lamination stamping dies (multi-stage progressive tools). These processes include the stamping and stacking of the laminations as a single process to improve production efficiency and reduce cost.

AUTOMATED WINDING OF THE STATOR

In an electric motor, an electrically conductive wire generates the magnetic field that turns the rotors. Adjusting the wire’s thickness and arrangement results in different operating behaviors. We have several types of automated winding capabilities (based upon In Runner or Out Runner Slotted Stator Designs): Needle Winding, Fly Winder and In-House Auto Winder. Our engineers modify motor winding configurations to adjust armature resistance, inductance, torque constant, and voltage constant.

INJECTION OVER-MOLDING

CMI has In House Injection Molding Presses that are utilized for the purpose of Over-Molding Stator Assemblies and Rotor Assemblies in order to meet harsh environmental requirements. This process can accommodate low, medium and high volume applications. This technique is ideal for creating identical, high-precision components. The process involves a few basic steps:

1. Injection. First, thermoplastic granules are melted into liquid form and then injected under high pressure into a metal mold.
2. Molding. Each mold features a cavity in the shape of the desired part. The thermoplastic material fills the mold completely, creating a precise shape.
3. Cooling and solidification. After injection, the molten plastic is left to cool and solidify within the mold.
4. Ejection. When the material has hardened, the mold is opened, and the finished thermoplastic part is ejected.

IN-HOUSE PRECISION MACHINING: STAMPING TOOLS, DIES, ASSEMBLY FIXTURES, AND GAUGES

CMI offers a range of in-house precision machining capabilities utilizing our own stamping tools, assembly fixtures, and gauges. Our facilities are equipped with state-of-the-art CNC, vertical and horizontal mills, and wire EDM machining technology.

Precision machining techniques are essential to the motor manufacturing process. Engineering will collaborate with our highly skilled machinists to develop tooling and fixturing that creates high precision parts with consistent quality across production runs. Whether you need to develop a prototype or launch large-scale production, we’re equipped to meet your needs.

Advantages of Precision Machining

Precision machining from CMI is faster than traditional manufacturing techniques, with reduced labor costs, less material waste, and many other benefits, such as:

VPI AND PARYLENE COATINGS

The products we manufacture must perform reliably under rigorous conditions. To improve performance durability, we offer vacuum pressure impregnation (VPI) and parylene coatings. These processes provide added protection for the porous materials often used to create transformers and motors.

VPI creates a void-free insulation system by impregnating a substrate with resin. Parylene is a conformal coating option, applied using chemical vapor deposition techniques in ultra-thin layers. A VPI (or more commonly referred to as “varnish”) provides structural integrity of the magnet wires in each of the respective slots to prevent dis-assembly. Parylene coatings are often used to provide environmental protection of electronics, as well as electrical insulation.