Machines for Hairpins, Busbars and Axial Flux Coils
Technologies/products exhibited:
Latest technologies in stator production
SNT - Our solution for setting and inserting hairpins into the stator package
Job coater for functional surfaces, e.g. for e-mobility
Our coatings are used, for example, as electrically insulating coatings on
Busbars
Filters for battery technology
plant linings
plant components in material handling
These coatings are based on the materials E-CTFE Halar, ETFE, Rilsan or PFA.
An overview of our portfolio can be found at www.adelhelm.de.
Measuring systems and instruments for process and quality control in the production and processing of magnetic materials
The magnetic properties of stators are a key criterion for the efficiency in electric drives and strongly influence the motor performance and range of electric cars. Important parameters are power loss, permeability and polarisation.
Process-related influences such as punching, packaging and housing strongly affect the magnetic properties. Studies show that the power loss can more than double over the individual process steps from the "electrical sheet to the stator in the housing". This can ultimately lead to e-drives not achieving the required key figures in the "end-of-line test".
BROCKHAUS MESSTECHNIK has developed test systems and sensors with which the magnetic properties can be efficiently and reliably measured in each production step from the sheet material to the stator in the housing.
The measurement data is used to optimise processes and, with the help of inline production control, to sort out possible defective stators at an early stage and thus avoid subsequent costs.
We are powering innovative, electric and digital mobility solutions in Baden-Württemberg...
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Expertise for change
A wide range of ElringKlinger components relating to e-motors, transmissions and inverters can be used in an electric drive unit. The design and materials of all our product solutions are tailored precisely to the relevant requirements – for maximum design freedom and functional reliability.
MetaloBond™ rotor/stator laminated stacks
The Institute for Factory Automation and Production Systems (FAPS) at Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU) focuses on the development of innovative manufacturing processes for mechatronic products.
The associated research group for electric machine production focuses on manufacturing processes for electric motors and contactless charging systems. From process development and optimization to recycling, the topic area of electric machine production is covered in a fully comprehensive, future-oriented and sustainable manner. The main areas of research are
Hexagon has extensive experience in the automotive industry and offers technologies for CAE simulations, for manufacturing and quality assurance to OEMs and the complete supply chain. At the "Reutlingen E-Mobility Days" we will show you
TubeInspect P16.2 HRC and P8.2 HRC for in-process measurement of busbars
!NEW! 3D Hairpin Inspect for setup of production machines and geometry inspection of serial parts next to the line
HPW is considered a leading manufacturer of winding wires for e-mobility and wind power and is thus one of the key companies in a rapidly growing future market.
As a specialist for PAI and PEEK-insulated copper flat wires, HPW has been a series supplier to numerous renowned European OEMs and Tier 1 manufacturers for several years with three production sites in Austria. A plant in North America for PEEK-insulated copper flat wires is currently under construction and will serve the first large-scale production in the USA from 2025.
As a technology leader, HPW manufactures PA12-insulated busbars with conductor cross-sections of up to 400 mm². The fully automated process covers the entire value-added chain from the raw material made of copper or aluminium to the finished insulated flat conductor. Aluminium busbars in particular meet the increasing demands of automotive customers for weight reduction, tight bending radii and temperature resistance of the insulation.
Produktionsforschung für die Elektromobilität
Das wbk Institut für Produktionstechnik des Karlsruher Instituts für Technologie (KIT) entwickelt gemeinsam mit seinen industriellen Forschungspartnern innovative Fertigungs- und Montageprozesse für elektrische Traktionsmotoren. Über die weitere Optimierung der Effizienz und Leistungsdichte hinaus werden im Rahmen der Forschungsarbeiten insbesondere die Verkürzung der Time-to-Market sowie die Reduktion der Produktionskosten adressiert.
Im Fokus der Messebeteiligung stehen flexible Produktionstechnologien für Statoren und Rotoren sowie digitale Prozessketten zur effizienten Werkzeugauslegung und intelligenten Prozessparametrierung:
Kinematische Fertigungs- und Montageprozesse für den schnellen und flexiblen Prototypenbau
Prozessmodelle für die Formgebung von Hairpin-Steckspulen sowie das Einbringen, Twisten und laserbasierte Kontaktieren von Statoren mit Hairpin-Wicklung
Maschinen- und Werkzeugfabrik GmbH
Bonding and sealing
Potting
Engineering
Service
The Chair "Production Engineering of E-Mobility Components" (PEM)
… at RWTH Aachen University was founded in 2014 by "StreetScooter" co-founder Professor Achim Kampker. In ten research groups, the team is dedicated to all aspects of the development, production and recycling of battery systems and their components as well as the fuel cell and the production of the electric drive train and entire vehicle concepts. The research group "Electric Drive Production" contributes to the economic, variant-flexible, future-oriented and sustainable production of the electric drive and its active components (rotor and stator). The focus is on investigating issues along the entire value chain - from the semi-finished product to the finished drivetrain and from the individual process to the holistic consideration of cross-process interactions. In accordance with the PEM philosophy of the "Innovation Chain", the team works on new and innovative technologies, always keeping an eye on the path to industrial application and solution scaling. Current topics of the research group are:
Laser Decoating
Laser Contacting
TRUMPF experts individually support in laser process development and realization with all technologies utilizing the know-how of our inhouse process development as well as experience from more than one hundred projects.
Guiding straightening and feeding of process materials
Quality Assurance for Electric Motors
Find out more about ZEISS eMobility Solutions. Their comprehensive portfolio provides support in every phase of the production of e-motors and subsequent assembly processes: