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This paper deals with the effects of welding, which is done to fix the stator stack, on a motor in case of fabricating a prototype motor that is manufactured in a small quantity. In the case of a small motor, the stator is designed and fabricated with the segmented core as a way to raise the fill factor of winding wire to the utmost within a limited size. In case of fabrication by welding both inside and outside of the stator in order to fix the segmented-core stator, the effects of stack are ignored, and the eddy current loss occurs. This paper performed the no-load test on an IPM-type BLDC motor for driving the suction fan of a vacuum cleaner, which was manufactured by using a segmented-core stator. As a result of the test, it was found that input power more than expected was supplied. To analyze the effects of welding by using the finite element analysis method and verify them experimentally, a stator was re-manufactured by bonding, and input power supplied during the no-load test was compared.

High-Speed BLDC Motor Design for Suction Fan and Impact on the Loss caused by Core Welding