Challenge
The customer wants to replace a pyramid-shaped stator segment made of SMC for its axial flux motor with a laminated stator segment. A connecting coupling should also be integrated in the stator segment for assembly. The simulations promise outstanding performance values.
Approach
We discussed the feasibility and production technologies in workshops. SWD then developed an overall concept: from the prototype phase to fully automated large-scale series and production at the customer’s premises. The prototype phase also safeguards the integrated coupling and its press-in and tensile forces. This means that the assembly process can also be greatly optimized. In addition, the material is even changed from NO to GO material. Here, too, SWD is working with the material supplier to develop a GO material that is suitable for series manufacturing and coated with bonding varnish (Backlack).
Success
The first punched stator segments were manufactured during the prototype phase. The punching tools are completely new developments that make it possible to punch different sheet sizes. The processability of the new material and the function of the coupling were thoroughly validated. We are currently in the ramp-up phase on the basis of our segmentation technologies with bonding varnish (Backlack). The first large-scale production system is in the planning phase.
