PEM Conducts Research to Reduce Tooling Costs for Electric Motor ProductionCopyright: © Röscher GmbH
The ongoing electrification of mobility is steadily increasing demand in the field of electric drives. To meet this market demand, hairpin technology has become established in e-drive motors in recent years. It offers high potential at both product and process level, mainly due to the defined manufacturing processes. On the other hand, the process chain is characterized by tool-bound manufacturing steps that can only be adapted to varying design features with great effort and at high costs.
Tool costs currently up to 200,000 euros
One of the main cost drivers is the process step of twisting in the production of hairpin stators for electric motors. This requires special tools with high demands on tolerance, accuracy, and strength. The corresponding investment for a tool set is therefore in the range of 100,000 to 200,000 euros, which is a considerable hurdle in terms of flexibility, especially in the prototype area.
Focussing on reduction of tool costs and delivery times
In the two-year "variTwist" joint project between PEM of RWTH Aachen University and the Berlin-based industrial partner Röscher GmbH, a marketable, flexible tooling system for twisting flat copper conductors shall be developed. The system shall be adaptable to the different variant drivers in hairpin stator production and thus bring with it the advantage of a massive reduction in tool costs as well as in delivery times, especially in prototype and small series production.
Further information is provided in this press release.
- "variTwist": Tool cost reduction through variant-flexible twisting processes in the hairpin stator production of electric motors
- Development of a marketable, flexible tooling system for twisting flat copper conductors in hairpin stator production
- Reduction of tool costs as well as delivery times, initially primarily in prototype and small series production
Research and project partners
- 07/01/2023 through 10/31/2025