A History of Air Core

Over the past 20 years we have developed the most advanced air core motors in the world. Striking a balance between what is possible in efficiency and commercially practical.

Why Air Core Electric Motors?

Air core electric motors are very different from conventional motors. Conventional electric motors utilize copper coils wrapped around steel cores to form motor poles for receiving magnetic flux. The steel cores used incur magnetic induced eddy current and hysteresis core losses, which inadvertently reduce the ultimate efficiency and the performance capabilities. Air core electric motors do not utilize steel cores to form poles. Instead, air core motors use air or non-magnetic materials inside their coils. These motors must be designed differently, but their ultimate advantage is that they do not incur the magnetic induced core losses of conventional electric motors.

Why Revolution Air Core Technology

Revolution’s electric motors utilize much better technology than other competing air core electric motor companies. Air core motors using PCB, or circuit board type, stators have lower performance, more costly material use, and they incur significant eddy current losses from the width of the traces (windings) exposed to the circumferentially varying magnetic flux as the rotor rotates. In contrast, Revolution’s stators utilize only advanced Litz wire for the highest possible efficiency. Litz wire strands (with hair-size cross-sections to the air gap magnetic flux) are many times smaller than circuit board traces, providing for dramatically lower losses.

Besides preventing eddy current losses in the stator, Revolution’s stators are also specially constructed with the copper windings all lying in a single layer to have the highest possible copper density. This translates to lower electrical resistance, lower resistive losses, a smaller magnetic airgap and the maximum possible product of (motor efficiency x power density) / (materials cost). You cannot do any better.