Stator segmentation: Material savings and CO2 reduction

Segmentation of the stator, or the division of the stator stack into circular segments, is a process with a bright future. You benefit from material savings, as there is no longer a dependency between the stator and rotor stacks. Each component can be manufactured separately from the ideal material. This also makes the punching tools smaller and more reliable.

New possibilities in motor design

New motor concepts become possible. Stator production can be optimized. The segments depend on the following parameters:

Groove division
Segment size
Connection/coupling between the segments
Tolerances, materials, and temperature ranges
Assembly
Insulation and winding
etc.

Holistic view when searching for solutions

This way, the optimal result is achieved:

The segments are bonded precisely.
The various improvements lead to a reduction in tolerances.
Driven by the precision of the segments, the diameter tolerances are reduced.
We reduce the height tolerance of the segments with our controlled bonding process. No distance compensation and constant lamination factor.
This simplifies the construction of the stator and improves the magnetic characteristics.

Benefits of stator segmentation

Highest precision

Bonded single teeth and segments are very precise and narrow diameter tolerances are possible. For all stator sizes.

Innovative brick process

Segmentation and layering in the brick process is a material-saving option based on our DKS® technology.

Independent choice of material

The independent choice of material for the stator and rotor enables optimization and completely separate production of the stator and rotor assemblies: A material with higher magnetic quality can be used for the stator and a material with higher strength for the rotor.

Environmentally friendly production

Segmentation reduces material requirements and thus also CO₂ emissions, paving the way for CO₂-neutral production.

What our employees have to say

“Stator segmentation is a process of the future, saves raw materials and is complety industrialized.”

Iwan Schneider

Production manager

Frequently asked questions about stator segmentation

What influence do segments have on the magnetic properties?

We achieve better magnetic properties thanks to the segmentation and thus the alignment of the rolling direction as well as the almost short-circuit-free connection of the laminations to each other by bonding varnish (Backlack) technology.

What tolerances are possible with segments?

This depends on the diameter, the number of segments, and the material thickness
With 18 segments, we have already achieved a diameter tolerance of less than 0.06 mm.

Engineering support

We support our customers from full circle stators to segmentation. We proceed as follows within the scope of engineering:

Discussion of the current design, geometries, assembly, materials, and quantities
Suggestion of 1 to 2 segment geometries incl. connection/coupling
Optimization of connection with the customer (mechanical, electrical, production-related)
Creation of dummies for validation and optimization
Production of prototype parts for testing

Workshop and solution finding

We discuss different solutions and define the procedure in workshops with your requirements, our experience, and our questions. This is our analytical approach.

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CDMC – Customer Development and Manufacturing Center

What makes SWD unique: We make new electric motor concepts with new lamination stacks possible. In workshops, we work with you to develop the lamination stack and the production processes (development). This is followed by the production of prototypes and series parts (manufacturing) at SWD. Following validation and ramp-up experience, production can also be relocated to you.

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Support through to series manufacturing

This is how we accompany you, the customer, through to series manufacturing:

Concept for serial manufacturing with investments, system technology, and budget for part prices
Implementation of agreed concept with production on SWD machine technologies
Production at SWD or on your premises

Future prospects with stator segmentation

SWD continuously improves segmentation technology. The complete segment production on our BPS® technology enables fully automated production, even on your premises. The segments can be manufactured to length with increasingly narrow height tolerances using jaws. With 100% diameter measurement, the diameter tolerances can also be reduced. With our expertise in the area of digitalization and manufacturing impact, we are entering new dimensions together with various customers.