Efficient stator production

In a project with an OEM, the companies LCD LaserCut AG (LCD), SWD AG Stator- und Rotortechnik (SWD) and PVS-Kunststofftechnik (PVS) realized the segmentation of the stator for a traction drive. Instead of a classic progressive cut for the stator and rotor plate, the stator was constructed in segments and its feasibility impressively demonstrated.

In close collaboration, laser-cut lamellas from LCD were first baked into precise stator segments using SWD’s BPS® baking technology. After optimizing the geometry and the coupling, the segment plates were punched and baked using a sample punching die. The precise and stable segment packages produced in this way were then overmolded with plastic by PVS using the stator insulation process developed by PVS. Using a joining device developed by LCD, the segments were precisely joined to the stator. The precision achieved in terms of roundness and diameter is comparable to that of a completely cut stator. The OEM equipped the stator, which is made of insulated segments, with hairpins and installed it in the motor housing. In addition to the massively reduced material costs, the first performance figures determined on the test bench are convincing and keep pace with reference motors.