Challenge
The customer builds a segmented micromotor with a diameter of less than 8 mm. The punch-stacked segments are not stable enough and the quality does not meet the requirements for medical technology. Customer contacts SWD for a better solution.
Approach
The very small segments are first sampled by means of eroding from a bonded electrical sheet block. SWD then develops a new tooling concept with punching, stacking, and, bonding of the smallest segments. The microsegments are reliably punched, stacked, and bonded in 9 lines during the prototype phase.
Success
Quality and strength far exceed current lamination stacks. This allows for more efficient production by allowing faster winding with a higher winding tension. The customer needs one less winding machine. The magnetic flux is better and the motor has a 15% higher power. In addition, the production of bonded stacks in nine lines is more cost-effective. Success on all levels thanks to bonding varnish (Backlack).
Facts
- 15% higher motor performance
- One less winding machine
- Higher winding tension and faster winding