![]() ![]() This was not previously possible for this technology and motor type. The combination of a special electric motor design, the winding process, and subsequent compression yielded an efficiency of 97.3% for a motor with an active length of 34 mm. With a process developed by Schaeffler for mechanical postcompression of the windings, a high slot fill factor can be achieved. This speaks for the use of single tooth winding. For this reason, the value for active length is typically low, but the diameter is relatively large. For example, for hybrid modules, the installation space requirements are decisive, especially since not only the motor but also one or more clutches must be situated in the tight space between the internal combustion engine and the transmission. It is ultimately the system-level requirements that determine which motor type and individual technological components are selected. The technologies tested in low volumes in Bühl will then be used in all plants worldwide. The Bühl plant will take on the role of lead plant, in whose pilot plant new technologies for agile electric motor manufacturing will be developed. By 2026 Schaeffler will have invested more than 500 million euros in building up manufacturing capacities at the plants in Bühl (Germany), Szombathely (Hungary), Taicang (China), Wooster (USA), and Puebla (Mexico). With such a strategy, it is also possible to respond flexibly to volume fluctuations in individual regions. The technology and the production equipment are globally standardized. The technology platform also covers process steps needed for manufacturing asynchronous machines one example is aluminum die casting for the rotor cage.īecause Schaeffler has long been pursuing a value creation strategy that is based on the motto “In the region, for the region,” the technology platform is ready to be deployed globally. The full encapsulation protects the magnetic materials from environmental influences and thereby makes passivation and elaborate surface treatment unnecessary. In the manufacturing of rotors for permanent magnet electric motors, Schaeffler makes use of transfer molding, in which the injected thermosetting plastic encapsulates the magnets and hardens. Through the acquisition of the special machine manufacturer Elmotec Statomat in late 2018, Schaeffler greatly expanded its expertise in the field of winding technology. A high level of flexibility is also needed for the process step of “winding” to accommodate not only the individual tooth winding but also the other established methods of hairpin winding based on the insertion of copper bars and continuous hairpin winding. Sheet metal utilization is thereby optimized and scrap is minimized. ![]() This means that the rotor and stator laminations for a motor are both stamped in one cycle. ![]() It uses the so-called progressive stamping approach. ![]() To enable a high degree of reusability across all product variants as well as flexibility in the setup processes, a modular, double-row concept was developed with the help of Schaeffler’s in-house toolmaking facilities. One example illustrating how the development goals of “efficiency” and “flexibility” can be united in highly automated manufacturing facilities is the tooling concept for stamping. Process and product innovations complement and promote each other, as is shown in this contribution by means of new electric motors as well as power electronics with an efficiency of more than 99%. Alongside this, a pilot plant for testing agile electric motor manufacturing technologies is being built in Bühl as the first of its kind in the world. Despite this, to enable rapid scale-up to volume production for as many vehicle classes and markets as possible, Schaeffler has developed a technology platform for flexible and economical electric motor manufacturing. The idea of having a standard electric motor that can be used in hybrid modules, dedicated hybrid transmissions, and electric axle drives will never become reality because the requirements differ so greatly. Innovative Electric Motors and Power ElectronicsĮfficient Scale-Up to Volume Production of Innovative Electric Motors and Power Electronics. ![]()
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