Digital twins and analytics: Millions of data records for better motors
SWD is a pioneer in the digitalized production of lamination stacks. Our systems provide countless items of process data about lamination stacks and the production process. As a result, our knowledge of the impact that the materials, tools, and processes have increases every day. This data provides the basis for continuously improving processes and consequently lamination stacks. As a side effect, we offer end customers complete traceability in accordance with the highest standards.
Zero-defect strategy with digital quality assurance
Our systems have already generated over 12 million data records concerning stator segments and over 1.5 million data records concerning full circle rotors. This data has allowed us to make the processes more stable and to achieve an error rate of around 0 ppm.
Reduced height tolerance of stator segments
Next, we quantified the impact of the material and the processes in production on the tolerances. As a result, we have reduced tolerances and improved lamination stacks. We are already reducing the height tolerance of stator segments thanks to our controlled bonding process. Our aim is to produce bonded segments with exactly the same height.
Reduced diameter tolerances of the segmented stator
The diameter tolerances of the segmented stator are also reduced. We have developed a method for measuring each stator segment in a group, meaning we have precise diameter measurements and can immediately see the impact of production. The aim is also to reduce diameter tolerances here, which also reduces the tolerance chains during assembly and increases the performance of the motor.
Advanced magnetic measurement in the production line
Magnetic measurement of the lamination stacks in the production line takes place in a further phase. A digital twin ensures continuous optimization of the process and process reliability. This means the impact of production on the motor’s magnetics can be quantified. When it comes to segments, we already do away with straightening the lamination stack and therefore prevent deterioration of the magnetics in the electric motor.
What our employees have to say:
“Digital twins with a clear reference ensure traceability at the component level. In many production processes, we have achieved 0 ppm.”
Sascha Erichsen
Quality and process manager
Why you should use digital quality assurance:
Complete component traceability and therefore maximum possible limitation of any deviations.
Complete knowledge of the production process and its impact on the mechanical and magnetic properties of the lamination stack.
Optimization of the production process to improve the lamination stack and thus the electric motor.
Knowledge of the impact of the material, its variances across production batches and therefore the opportunity to optimize the material.
It is the basis for precisely evaluating the tolerances of new components and ensuring there are no surprises when ramping up series manufacturing or in series production.
Success stories
Impressions
