Challenge
The customer, an automobile manufacturer, builds their electric drives on the basis of segmented stators with 12 or 18 segments. Extremely narrow diameter tolerances of +/- 0.032 mm (!) are needed to fit these into the housing, with segments approx. 100 mm long made of NO20 material.
Approach
SWD discusses the requirements, feasibility, and measurement methods for safeguarding these tolerances with the customer. Current productions and our digital production data from BPS® technology serve as the basis for evaluation.
Success
The prototype phase with three different geometries/diameters was successfully completed. The two-track punching tools and the 16 bonding cavities were sampled and the variance of the stator diameter is within 0.02 mm – measured with a stepped diameter sleeve. We have developed a new type of 100% diameter measurement for production with our BPS® technology and will carry out a diameter measurement with each segment. This means that we are setting new standards in feasibility!
Facts
- Diameter tolerance of individual teeth of +/-0.032 mm
- 100% diameter measurement in the fully automatic system
- Further tolerance reduction under appraisal