Axial flux technology continues to gain momentum

Axial flux motor technology is already used in various applications. In recent years, SWD AG has developed and perfected the production of “pyramid-shaped” stator segments to the point where they can be industrialised for large series. This means that segmental axial flux motors can be manufactured efficiently and faultlessly to automotive standards.

SWD AG is now building the world’s first and only production lines for axial flux segments for the series start-up and production of axial flux motors at one of our customers. For the basic development, we have pooled our material, process, tool, machine and data expertise and developed a solution that is suitable for series production and industrialization.

The material is a GO (grain oriented) electrical steel. Together with the manufacturer, we have optimised the material and the baked varnish  coating to improve strength at higher temperatures.

The processes are adapted to the material and the tools and optimised to reduce the baking cycles and increase the strength. In addition, the processes are optimised using intelligent control solutions so that the pyramid shape is maintained despite the different shrinkage behaviour of the baking varnish.

The material used is GO (grain-oriented) electrical steel. Together with the manufacturer, we have optimized the material and the baking varnish coating to ensure better strength even at higher temperatures.

The processes associated with the material and tools have been optimized to shorten the baking cycles and increase strength. Additionally, the processes have been refined with intelligent control solutions to maintain the pyramid shape despite the varying shrinkage behavior of the baking varnish.

The tools are a new development from SWD with a special design. This allows a high number of strokes with high stability, which is more difficult to achieve with GO material than with standard electrical sheet materials.

The machine technology is based on our proven BPS® technology. With more than 20 million segments produced and installed, this technology is proven and enables 0ppm production.

According to our standard, a digital twin is created for each component and stored in a central database. All data is stored in this digital twin, from the material and tools used to the machining and measurement data. Each dataset can be immediately mapped to a DMC on the part, creating a 1:1 link between the digital and physical worlds.