E-Motor Research Site CologneCopyright: © PEM RWTH Aachen University | Patrizia Cacciotti
On an area of more than 1,000 square meters in Cologne, the chair of Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University, together with Ford and other partners from industry and science, is researching one of the most important e-motor components: the so-called hairpin stator. As part of the HaPiPro2 project, the production technology for different variants of this e-motor component, which is crucial for performance and efficiency, is being advanced on a prototype demonstration line. The project is funded by the state government of North Rhine-Westphalia.
Different e-motor variants on just one production line
The infrastructure maps all the process steps from hairpin production through assembly processes and laser welding to impregnation and insulation. The aim of the project is to make the previously complex production of electric motors significantly cheaper in the future and thus shorten their time to market. The efficient method of producing different electric motor variants on a single line should also make a significant contribution in the future to saving raw materials and energy and reducing waste. The hairpin stators are to be produced at the new research facility in both truck and car engine sizes using the same machines and processes. This methodology should help make the entire production process for electric motors more flexible, efficient, and sustainable.