• * Electro Sheets
  • * Sample Connectors
  • * Pre-production Springs for Validation
  • * Prototypes and Smaller Batches in Contacts
  • * Smaller Batches in Cable-Shoes
  • * Prototype Busbars
  • * Sample Parts Brush Holder, etc. Mounted for Functional Tests
  • mechaSYS GmbH, Christinstr. 18, 75177 Pforzheim, Germany

Electrical Sheets: Rotor- und Stator-Sheets by Full Service


 

Due to the growing demand for electrical sheet metal, we have bundled our technological resources and expanded the production of pure sheet metal blanks to complete packages in stator and rotor sheets. Therefore, we are able to provide our customers with the service of complete sheet metal stacks, baked, laser-welded or punched packaged in the electrical steel sector. We manufacture for the sectors of e-mobility, power tools and machines as well as inductivities for bobbins and magnetic switches or transformers.
Due to our extremely thin cutting gap of just 0.07mm - as much as diameter of a human hair - we are able to produce the smallest contours.

The extreme power density at a max. Laser power of 1000 watt enables electrical sheets based on baked varnish systems with the lowest possible edge zone melting - burr-free. Magnetic pockets close to the edge with a web width of 0.35mm with a sheet thickness of 0.50mm are possible. Everything 100% “Made in Germany” in packaged quality - usually tolerance class T7.
Usual delivery times are approximately 1 week for pure cutted parts, 3 weeks if a baking or welding device is required.
Should our extensive material store in non-grain-oriented electrical steel not meet your needs, we are in contact with all well-known electrical steel manufacturers (such as Cogent, Tata, ThyssenKrupp, VoestAlpine, Wälzholz, ...) and can get it in short term if necessary.

 

All out of one Hand:
Electrical Sheet metal on stock, laser-cutting, stacking of baked lacquer sheet or welding - FINISH.

Your Advantage:
one partner for your prototype of electro sheet application in rotor- and stator-sheets, additional time for planing and set-up of your serial production.

 

Process-Steps:

  • data preparation and set-up of jigs,
  • laser cutting from electrical steel sheet that is in stock or provided by the customer (ideally in sheets, maximum half/ divided middle format 1,250 x 1,250mm),
  • alternatively: punched for the production of single teeth in complete cut,
  • measuring und approval of the first piece,
  • production with measurement accompanying production,
  • packing and connection technology (laser welding or using baking varnish for oven od inductive) of electrical sheet assemblies (rotors, stators or individual teeth),
  • checking the package height,
  • final product.

 

Following Examples
realised parts:

 Sheet Metal and Final Parts of Electro Sheet

 

Stock Material: 

M235-35, M235-50, 
M270-35, M270-50, 
M330-35, M330-50, 
M350-35, M350-50, 

M400-65A2, 

M800-65A, 
NO20-15 Backlack, 

NO20-15 C5, 
NO30-1500A Suralac7000, ...

 

New Development in mid-range qauntities up to mass production:

In addition to the usual sample numbers of a few to perhaps 100 rotors or stators, it has been possible to reproduce series of several 1,000 pieces with manageable tool costs. On the one hand, the flexibility of laser technology can be used or completely punched sheets can be processed. As far as connection technology is concerned, you as the customer have a free choice: Baked varnish in series or a familiar interlock system - depending on the individual application and the maximum permitted eddy current losses.

The main advantage: this technology allows rotors to be built up relatively easily in addition to common prototype structures.

Regardless of whether every or every nth new sheet of sheet metal is to be rotated by full tooth segments relative to one another or rotors are only to be turned on - the subject of minimizing cogging by means of twist. Can be implemented with this technology.

In other words: There is almost no limit to the imagination of the developers!

 

 Advantage:

  • high flexibility of production with medium lot sizes and high product variance
  • high process reliability due to the decoupling of the gluing process from the press in a separate module,
  • reduction of the downtimes of the producing press, thus higher output and thus ultimately lower unit costs,
  • packages true to size like from a progressive tool,
  • rotated packages can be produced fully automatically,
  • system can be converted to punch packaging,
  • easy tool change,
  • manufacture of rotor from stator can be implemented.

 

Modular Packaging Unit

 

 

Selection guide for your rotors or stators:

The following is a comparison of individual structures for optimal comparability of samples to series:

 

  advantage disadvantage

"Backlack" glueing

  • optimal structure with regard to eddy current losses,
  • good, simple suitability for samples,

  

 

  • Series process somewhat more complex due to baking time
  • fast "Backlack"
    backing time < 2 Minuten)

"Backlack" and interlocks

  • good, simple suitability for samples,
  • high comparability to series with punched interlock system
  • "Bridge technology" between baking and interlock
  • only for samples

Interlock punched

  • Combination of laser-cut sheets with punched interlock for samples possible
  • Invest punching tool for patterns,
  • Invest series / stamping process, large series

Laser Welding/ WIG-Welding

  • Laser cutting and wleding in combination feaseable 

 

  • Active current losses in the rotor can have a detrimental effect

 

Possibilities of Stator Assemblies:

mögliche Statoraufbauten

top left: complete Stator | top middle: I-Segment | top right: T-Segment

bottom left: Pol Star | bottom middle: Pol Shell | bottom right: Pol Chain