Technology expertise for the e-mobility of tomorrow
Electromobility enables new mobility concepts
The steady trend toward urbanization makes the use of electric drives indispensable. This is the only way to limit emissions and enable sustainable mobility. At the same time, the use of highly efficient electric motors enables entirely new mobility and logistics concepts, such as air cabs and transport drones. Innovative manufacturing technologies are needed to realize these concepts. ELMOTEC STATOMAT’s winding technology makes a decisive contribution to this.
- Compact design
- High number of wire crossings without “special pins”
- Fewer welding spots for higher process reliability
- Especially suitable for stators with a high number of slots
On the road to sustainable mobility, vehicle manufacturers relied on different electrification strategies.
With its in-depth process know-how and extensive equipment portfolio, ELMOTEC STATOMAT offers production solutions for a wide range of drive concepts.
As an industrialization partner, ELMOTEC STATOMAT accompanies its customers from the production-ready design of stators, through initial samples, to a production-ready manufacturing process.
If required, ELMOTEC STATOMAT’s experts provide support during the production ramp-up, thus ensuring that the processes are optimally adapted to the customer’s needs. In this way, we ensure the highest product quality and plant availability.
With the final industrialization of flat wire wave winding technology, we enable our customers to set new benchmarks in the field of power density.
Due to a significant reduction of critical production steps and a modular line design, this technology is ideally suited for the series production of electric drives for electromobility.
Applications in the field of e-mobility
For typical applications in the field of e-mobility, from hybrid modules to e-axles or wheel hub motors, Schaeffler ELMOTEC STATOMAT offers the appropriate winding technology and customized industrialization solutions.
- Twist-free winding for up to 30 parallel round wires
- Flat wire wave winding for maximum power density especially at high slot counts
- Linear winding for round and flat wire windings, ideal for minimum installation spaces and for achieving high fill factors.
The trend toward new mobility – such as e-mobility, alternative mobility concepts, connectivity and autonomous driving – is impacting products and business models alike. Key drivers of this are rapid regulatory and technological change, increasing urbanization, and growing social awareness of the negative environmental impact of traditional mobility concepts. At the same time, there is a growing preference for new electrified drive technologies over conventional combustion engines.
E-motors with highest efficiencies and compact design
The effective implementation of new mobility concepts requires mechatronic technologies at component and system level. Especially in the area of electrified powertrains, the limits of what is technically feasible are being pushed further and further. Electric traction motors with the highest efficiencies combined with compact design and minimal weight are presenting manufacturing technology with ever new challenges. The coil winding technology in particular has a significant influence on the final motor performance. A compact and precise winding design not only reduces the space required, it also ensures suitable inductance and consistent electrical resistance. With ever higher mechanical fill factors, faultless insulation of the winding is crucial. Only maximum precision in the manufacture and assembly of the winding can prevent damage and thus guarantee a long operating time.
With innovative solutions in the field of winding technology, Schaeffler ELMOTEC STATOMAT makes a significant contribution to the feasibility of highly efficient drive trains for e-mobility.
