The future of electromagnetic Components: Focus on Quality and Manufacturing

More than just Dimensions and Material – Quality through Manufacturing Control

In addition to the material quality of the lamination steel, numerous manufacturing factors influence the quality and performance of the lamination stack, or more precisely, the electromagnetic component.

Typical influencing factors include:

• Straightening the material prior to punching, can have a negative effect on magnetics;
• The quality of the cut edges when punching the laminations largely depends on the precision and condition of the tool; poor cut edges lead to increased magnetic losses.
• The connection technology between laminations significantly affects electrical and mechanical properties, ranging from a short circuit (e.g. stamped packings) to complete insulation.
• The connection method also determines additional parameters such as strength at room temperature and at higher temperatures as well as long-term stability under thermal stress (e.g., creep behavior).
• Tight tolerances and more precise components reduce overlaps during assembly and decrease electromagnetic losses.

Numerous experts have already investigated these issues and proven their influence.

Gentle Manufacturing and Intensive Control

At SWD AG, we have invested many years in analysing and optimising our manufacturing processes. In the production of bonded (Backlack) stator segments, for example, we conduct thorough strength and quality tests, such as cracking tests to assess load capacity, as well as analyses of behavior at high temperatures and under stress (creep behavior).

Through continuous data collection — for example, by measuring diameters 100% of the time during series production — we reduce tolerances and thus electrical losses caused by high overlaps during assembly. Material selection, the quality of cutting edges, and the Bakclack bonding process substantially influence the behavior in regard to short cuts. Currently, we are performing series measurements to further improve resistance values and quantify manufacturing influences. We also measure the electromagnetic quality of lamination stacks to further optimise production processes.

Digital Data Linking for Maximum Efficiency

Our systems are fully integrated. Since the introduction of BPS technology, we have created a digital twin of every stator segment manufactured. We use this data foundation to continuously improve our processes and gain a better understanding of the factors that influence them.
100% in-line testing and the digitization of sample measurements significantly increase transparency and consistency. All measurement results are stored in a central database and linked to components via reference codes (e.g., DMC). This allows us to carry out real-time evaluations and identify potential influencing factors at an early stage.

Using “Big Data” analysis tools, we can identify patterns and correlations, such as shortcuts in stacks. This allows us to isolate specific influencing factors, whether relating to materials, tools or manufacturing processes, and implement continuous improvements to meet rising requirements. This data foundation and our expertise enable process-secure production and allow us to conduct highly accurate feasibility analyses, demonstrating our competence in evaluating the manufacturability of new customer components. We can provide comprehensive advice and demonstrate the behavior and achievable tolerances based on real data, creating added value in the design and development of electric motors.