This article has been supervised based on the advanced technical expertise and insights we have cultivated since our founding in 1919 as a leading company in plastic processing. Our department continuously analyzes market trends and the latest technologies in ultra-compact, high-precision micro motors, focusing on providing high-value-added information to designers and developers. As a team of experts with in-depth knowledge of product characteristics, we support our customers\u2019 problem-solving and technological innovation by delivering accurate and practical content.<\/p>\n
\u3002<\/span><\/span><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n <\/p>\n Motor heat generation is primarily caused by three types of losses: copper loss, iron loss, and mechanical loss.<\/p>\n The impact of these three factors varies depending on the motor type, design, and operating conditions. Generally, copper losses tend to dominate in small motors due to winding resistance, while iron losses tend to increase at high speeds. Understanding the mechanisms of these three types of losses is the first step toward implementing appropriate measures for heat generation. Below, we will examine each type of loss in detail.<\/p>\n Topics Covered in This Section<\/strong><\/p>\n Each type of loss has a different mechanism of occurrence, and their impact varies depending on the motor type and operating conditions. Particularly in development environments dealing with small motors<\/a>, countermeasures against copper losses are key to suppressing heat generation.<\/p>\n <\/p>\n Copper loss is the power loss generated by the resistance of the motor coil windings and the electric current flowing through them.<\/p>\n This loss is expressed by the power formula P = I\u00b2R<\/a> (electric current squared \u00d7 resistance) and is proportional to the square of the electric current.<\/p>\n Therefore, theoretically, halving the electric current reduces heat generation due to copper loss to approximately one-fourth.<\/p>\n Although this varies depending on the application and design conditions, in motors where high electric currents flow through the coils, copper losses are often the primary cause of heat generation, making them a critical factor in heat management.<\/p>\n \u00a0[Design Methods to Reduce Copper Losses]<\/strong><\/p>\n By combining these methods, it is possible to effectively reduce winding resistance and suppress heat generation caused by copper losses. In small motors used in medical equipment and optical equipment, optimizing the windings during the design phase leads to improved performance and a long service life.<\/p>\n <\/p>\n Iron losses are losses generated in the iron core due to changes in the magnetic field and consist of hysteresis losses and eddy current losses.<\/p>\n Hysteresis loss is the energy loss that occurs inside the iron core during repeated magnetization and demagnetization, while eddy current loss arises when induced electric currents flow within the iron core due to a fluctuating magnetic field.<\/p>\n This phenomenon becomes particularly noticeable when motors with iron cores operate at high speeds. In medium- and large-sized motors, in particular, laminated steel sheets are used to suppress eddy current losses. On the other hand, coreless motors lack an iron core, and iron losses such as hysteresis and eddy current losses do not occur in principle.<\/p>\n Takiron CI\u2019s coreless motors<\/a> offer the advantage of suppressing heat generation caused by iron losses even during high-speed rotation due to this structural characteristic.<\/p>\n For applications in industrial equipment and optical equipment that require high-speed, high-precision operation, a motor structure free of iron losses is an effective choice.<\/p>\n <\/p>\n Mechanical losses are losses caused by friction within the motor and air resistance.<\/p>\n This includes frictional heat at the contact points between the bearings and the shaft, as well as wind loss (loss due to air resistance) caused by rotation; however, the proportion of total heat generation is relatively small. While this varies depending on the motor type and operating conditions, it generally accounts for about 3\u201312% of total losses. However, if operation continues with degraded lubricating oil or grease, frictional resistance may increase rapidly, and frictional heat may rise significantly.<\/p>\n In applications requiring long-term maintenance-free operation, such as security equipment and safety equipment, careful consideration of these mechanical losses is necessary.<\/p>\n Mechanical losses can be minimized by selecting high-quality bearings and grease and performing regular maintenance.<\/p>\n <\/p>\n Excessive heat generation in a motor not only causes the temperature to rise but also inflicts serious damage on the internal components of the motor.<\/p>\n The effects of heat generation extend across a wide range of areas, including insulation materials, mechanical components, and electrical characteristics, ultimately leading to a shortened motor lifespan and sudden failure.<\/p>\n In medical equipment and safety equipment, such failures directly affect patient and operator safety, so it is crucial to correctly understand the specific effects of heat generation.<\/p>\n The following section explains the typical adverse effects of heat generation.<\/p>\n Contents of this section<\/strong><\/p>\n These adverse effects are interrelated, leading to a chain reaction where one problem triggers others. Proper heat generation management can help minimize these risks.<\/p>\n <\/p>\n The insulating coating covering the coil surface deteriorates in high-temperature environments.<\/p>\n The permissible temperature varies depending on the heat resistance class (B, F, H, etc.). As the temperature approaches the permissible limit, insulation degradation accelerates; therefore, it is crucial to incorporate a safety margin in the design that accounts for the class and temperature rise.<\/p>\n If the insulation coating is damaged, a short circuit can occur between coils, leading to a vicious cycle where localized high electric currents further exacerbate heat generation. Ultimately, this poses a risk of coil burnout or fire; damage is particularly likely to spread in motors used within enclosed housings, where heat dissipation is difficult.<\/p>\n In medical equipment and industrial equipment, sudden equipment shutdown due to insulation breakdown can directly endanger patients\u2019 lives or halt production lines; therefore, the heat resistance of insulation materials and temperature monitoring are of the utmost importance.<\/p>\n <\/p>\n If high temperatures persist, the grease\u2019s viscosity decreases, causing it to leak out, or conversely, the grease hardens, reducing its lubricating performance and causing it to fail.<\/p>\n If the oil film breaks down, direct metal-to-metal contact occurs, leading to increased frictional resistance that generates further frictional heat, creating a vicious cycle of rising temperatures. In the worst-case scenario, the bearing seizes, the shaft locks, and the motor comes to a complete stop.<\/p>\n In applications requiring continuous operation and long service life\u2014such as electronic locks in security equipment or drive mechanisms in medical equipment\u2014measures to prevent thermal degradation of bearings and grease are essential.<\/p>\n Selecting high-quality grease capable of maintaining performance even in high-temperature environments, along with regular replacement and maintenance, leads to an extended lifespan for the bearings.<\/p>\n <\/p>\n Heat generation causes the electrical resistance of the coil to increase, making it harder for electric current to flow, which reduces output torque.<\/p>\n Copper wire has the characteristic of increasing resistance as temperature rises; for every 10\u00b0C increase in temperature, the resistance value increases by approximately 4% . Furthermore, in motors using permanent magnets, magnetic force weakens due to thermal demagnetization at high temperatures, causing a significant decline in motor performance.<\/p>\n The permissible temperature of neodymium magnets varies by grade; in standard grades, permanent demagnetization can occur starting around 80\u00b0C. Ferrite magnets are relatively resistant to high temperatures, with approximately 250\u00b0C serving as a general guideline. The resistance of electronic components also increases with rising temperatures, leading to higher power consumption and reduced efficiency.<\/p>\n In lens drive motors for optical equipment and industrial tools, such performance degradation directly affects product accuracy and work efficiency; therefore, performance changes caused by heat generation must be thoroughly considered during the design phase.<\/p>\n <\/p>\n There are three approaches to suppressing motor heat generation: implementing a cooling system, optimizing operating conditions, and selecting the appropriate motor.<\/p>\n For existing motors, enhancing heat dissipation through cooling fans or heat sinks is effective, and heat generation can also be significantly reduced by reviewing operating methods.<\/p>\n For new designs or model changes, selecting a motor structure with low heat generation provides a fundamental solution.<\/p>\n The following sections provide detailed explanations of each of these measures.<\/p>\n Contents of This Section<\/strong><\/p>\n These measures are not only effective when implemented individually but also yield greater results when combined. Particularly for existing systems where heat generation is a major issue, introducing these measures in stages will allow for improvements while minimizing risk.<\/p>\n <\/p>\n Forced cooling using cooling fans or the installation of heat sinks effectively promotes heat dissipation from the motor.<\/p>\n In industrial machinery, using motors equipped with cooling fans can prevent overheating during prolonged operation.<\/p>\n Replacing mounting plates with aluminum\u2014which has high thermal conductivity\u2014or increasing their thickness are also effective ways to enhance heat dissipation.<\/p>\n When used inside a sealed enclosure, airflow can be created by adding heat dissipation fins to the enclosure itself or installing a small fan inside.<\/p>\n For applications requiring quiet operation, such as medical equipment and optical equipment, natural cooling systems utilizing heat pipes are also an option. However, since adding a cooling system increases space requirements and costs, thorough consideration is necessary during the design phase.<\/p>\n <\/p>\n Reducing the electric current can significantly reduce copper losses, which are proportional to the square of the electric current.<\/p>\n If the motor\u2019s operating cycle allows, set longer idle periods to ensure sufficient cooling time.<\/p>\n Avoiding overload conditions and strictly operating within the rated torque range is also crucial for suppressing heat generation.<\/p>\n For industrial tools and hobby products, optimizing the duty cycle (the ratio of continuous operation time to idle time) according to usage patterns allows you to maintain the necessary performance while suppressing heat generation.<\/p>\n Setting the supply voltage to the appropriate level is also a basic measure to reduce unnecessary electric current and suppress heat generation.<\/p>\n If the driver circuit has a function for controlling the electric current, further heat generation can be reduced by optimizing the electric current according to the load.<\/p>\n Conducting regular operational checks and temperature measurements to detect signs of abnormal heat generation early on is also an effective means of ensuring long-term stable operation.<\/p>\n <\/p>\n Brushless motors eliminate friction loss from brushes, making them a design with high efficiency. However, heat dissipation is greatly influenced by design factors such as inner\/outer rotor structure, housing shape, mounting conditions, and heat escape routes (thermal paths).<\/p>\n Since coreless motors lack an iron core, they do not generate iron losses, enabling high efficiency and low heat generation.<\/p>\n Takiron CI\u2019s coreless motors are adopted in applications requiring high precision, such as medical equipment and optical equipment, due to these structural characteristics. Furthermore, the company\u2019s Brushless motors feature a long service life and low vibration (quiet operation), making them suitable for industrial equipment and security equipment.<\/p>\n If space permits, increasing the motor size allows for operation at a lower electric current while maintaining the same output, thereby reducing heat generation.<\/p>\n When designing new systems or upgrading existing ones, considering a switch to these low-heat generation motors can simplify cooling systems and reduce maintenance frequency.<\/p>\n <\/p>\n Motor heat generation stems from three types of losses\u2014copper loss, iron loss, and mechanical loss\u2014and can lead to serious consequences such as insulation degradation, bearing burnout, and performance degradation.<\/p>\n Effective countermeasures include installing cooling systems, optimizing operating conditions, and switching to motor types that generate less heat. In particular, Coreless motors and Brushless motors are structurally designed to suppress heat generation and contribute to a long service life.<\/p>\n At Takiron CI, we offer coreless motors with no iron losses and Brushless motors with excellent heat dissipation, providing optimal solutions tailored to our customers\u2019 specific applications.<\/p>\n Let\u2019s enhance motor safety and reliability through proper heat generation management to ensure stable product operation.<\/p>\n <\/p>\n \u00a0<\/span><\/p>\n Product Information & Inquiries<\/span><\/p>\n For more details on C.I. Takiron\u2019s micro motor products, please visit the website below.<\/p>\n If you are having trouble selecting a small motor for your product development, please feel free to contact us via the inquiry form. Our technical staff will discuss your application and requirements with you and propose the optimal solution.<\/p>\nMain Causes of Motor Heat Generation<\/h2>\n
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Heat Generation Due to Copper Losses<\/span><\/h3>\n
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Heat Generation Due to Iron Losses<\/span><\/h3>\n
Heat Generation Due to Mechanical Losses<\/span><\/h3>\n
\u00a0Adverse Effects of Motor Heat Generation<\/h2>\n
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Deterioration of Insulation and Coils<\/span><\/h3>\n
Deterioration of Bearings and Grease<\/span><\/h3>\n
Performance Decline and Reduced Efficiency<\/span><\/h3>\n
Measures and Prevention Methods to Reduce Motor Heat Generation<\/h2>\n
![\"CAUSES](\"https:\/\/cik-ele.com\/wp-content\/uploads\/2026\/04\/3a76837cc6ee1cce24fa2a6681241c89-1-540x360.jpg\")
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Enhancing Heat Dissipation with Cooling Systems<\/span><\/h3>\n
Optimizing Operating Conditions<\/span><\/h3>\n
Switching to a motor with lower heat generation<\/span><\/h3>\n
Summary<\/h2>\n
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