Technologies for segmentation

Technologies for segmentation: Fully automated bonding varnish (Backlack) lines for stator segments

We developed BPS® technology for the industrialization of the bonding varnish (Backlack) stator segments. The highly automated BPS® systems are perfectly matched to the material and geometry. Segmentation saves material and CO2. High process reliability with a digital twin ensures continuous process optimization to achieve 0 ppm.

Ensure efficient production of stator segments and single teeth with BPS® technology

Our BPS® technology is a fully automated system for the production of bonded stator segments or single teeth. The system contains all processes from unrolling the raw material to the finished lamination stack, including measurement and testing methods. As a result, we have already supplied more than 15 million stator segments to the automotive industry.

The next level of stator production with DKS®

Another development is our DKS® technology. With this technology, the segments are not manufactured individually. Instead, lamination segments are stacked in a staggered manner – just like with a brick wall. The staggered lamination segments are bonded to create a solid stator. DKS® technology was originally developed by SWD for smaller motors in serial manufacturing.

We are currently scaling the technology to large stators and large volumes.

What our employees have to say:

“BPS® technology saves an enormous amount of material, has been tried and tested millions of times, and achieves 0 ppm.”

Iwan Schneider

Production manager

Why you should use technologies for segmentation:

Reduced magnetic losses

The material is not aligned for punching, resulting in fewer magnetic losses. Read more in our blog article.

Manufacturing automation

Fully automated production process from the unwinding to the finished stack.

High process reliability

Maximum process reliability is ensured by the precise coordination of material, tools, process, and machine. Everything is monitored, measured, digitized, and documented.

Continuous process optimization

A digital twin is used for tracking, analyzing, and improving processes. “Big data meets big improvement” is our approach.

Intelligent process control

Intelligent process control intervenes in the recipes and increases both the output and the stability of the process.

Flexible production location

Production on your premises or at your manufacturing partner’s premises becomes possible.

Fully automatic 3D axial flux motor segmentation

Fully-automated segmentation is also possible for axial flux motor 3D segments. Each lamination has a different size. Pyramid-shaped segments are possible.

Material-saving and environmentally friendly

Both segmentation methods save material and thus reduce the carbon footprint.

Success stories

About us | Segmentation | Processes & Industrialization
07.09.2019 - Reading time: about 7 minutes
Electromobility is on its way. The momentum is increasing and the migration from the combustion engine to hybrid and fully electric models has begun. Major changes are about to take place, not only in the vehicles themselves, but also in the value chains.
Read full article
Segmentation
08.05.2021 - Reading time: about 1 minute
The segmented stator with plastic overmolding is the answer to rising raw material prices, increased engine performance and smart production.
Read full article
Segmentation | Processes & Industrialization
20.11.2021 - Reading time: < 1 minute
The BPS® technology for the fully automated, fast, efficient, and energy-saving production of stator segments has been developed and mass-produced by SWD with partners such as Schuler, GF and others over the past 10 years.
Read full article
Processes & Industrialization | Success Stories
21.10.2022 - Reading time: < 1 minute
We reduce tolerances! The customer, a vehicle manufacturer, builds their electric drives on the basis of segmented stators with 12 or 18 segments.
Read full article
Quality | Segmentation
05.12.2023 - Reading time: < 1 minute
We have built the first BPS® machine with 100% diameter measurement. The result is even narrower stator tolerances.
Read full article

Impressions

Our specialist will be happy to answer any questions you may have.

Fact box

  • From the idea to the industrialization of SWD
  • Experience from over 12 million stator segments
  • Intelligent process control
  • Digital twin ensures continuous process optimization
  • Saves material
  • 100% traceability
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