Segmentation has the advantage that stator and rotor can be manufactured from completely different materials and using different lamination processes. This allows the best to be achieved for both stator and rotor, without consideration for the manufacturing steps.

With the same material and lamination process for stator and rotor, segmentation provides no advantages. No material is saved and the costs will not be lower than in classical manufacturing. As soon as this premise no longer applies, segmentation is the only way forward. Many new possibilities open up in one step.

Your current solid stator forms the basis. Based on your requirements, we examine possibilities and variants. This includes materials, segment size, connections, tolerances, housing fits as well as manufacturing processes according to our holistic approach.

Industrializable geometries of segments including connections are created by us in the CAD model. This allows you to perform your simulations and optimize together with us for both magnetics and manufacturability.

In the solid stator, the magnetic preferred direction (rolling direction) is distributed across the stack height by rotating the laminations. With segmentation, each segment has the identical magnetic preferred direction and the stack becomes more homogeneous or isotropic. If the rolling direction is placed in the direction of the highest flux density, this results in a reduction of losses. The small air gap between segments increase losses minimally. In the overall assembly, these effects at least cancel each other out. As a rule, losses are slightly reduced. Due to the more homogeneous stack, torque ripple becomes smaller.

The diameter tolerances in the assembly of segments depend on various factors. Material and lamination process define the repeatability of individual segments, the number of segments influences the tolerance range. The punching process influences the change over the wear condition of the punching tool. Our technology achieves the tightest tolerances. This is demonstrated by means of fully integrated measuring systems. In series production, we implement 100% diameter measurement of segmented stators upon request. This allows you to reduce the clearance to the housing, among other things, which manifests itself in mechanical stresses and thus lower magnetic losses.

We perform the classic mechanical measurements including 100% measurement of the diameter in assembly. Then we have productions today where we test the strength of components in series production (see digital twin), determine cleanliness, measure coercive field strength and measure insulation resistance. This qualifies the components as it is later relevant in the electric motor. Naturally including all measurement protocols via our digital twins.