rotor bg 2-2

Design, Construction and Manufacturing

We design your cus­tomized elec­tric motor, addi­tion­al­ly we help you with the con­struc­tion and man­u­fac­tur­ing of the elec­tric motor.

1. Design of Motors

Accord­ing to your wish we design any type of elec­tric motor. You will get from us a com­plete com­par­i­son of all influ­enc­ing fac­tors, such as the num­ber of pole pairs or the num­ber of slots of the sta­tor. You can choose if you want a motor design which is suit­able for medi­um or high vol­umes. Our main focus is always to select an elec­tric motor design that can be pro­duced cost-effectively.

Our ser­vices:

  • Elec­tro­mag­net­ic design of elec­tric motors
  • Cal­cu­la­tion of char­ac­ter­is­tic curves and maps
  • Elec­tric motor type selec­tion and comparison
  • Elec­tro­mag­net­ic sim­u­la­tion 2D and 3D
  • Ver­i­fi­ca­tion of elec­tric motor design
  • Effi­cien­cy optimization
  • Max­i­miza­tion of con­tin­u­ous power
  • Struc­tur­al analy­sis of shaft, bear­ing and housing
  • Ther­mal sim­u­la­tion of the elec­tric motor
  • Design of motor cool­ing and dimensioning
  • Soft­ware opti­miza­tion of dri­ve and control
  • Acoustic opti­miza­tion and NVH analysis
  • Patent research of new elec­tric motor types
  • Series design and man­u­fac­tur­ing optimization
  • Cost opti­miza­tion of rotor and stator
electric motor design and efficiency map
electric motor construction

2. Construction of Motors

We help you to cre­ate all draw­ings and parts lists to build up a com­plete elec­tric motor. This also includes elec­tric motor hous­ings with cool­ing solu­tions as well as shafts and bear­ing sys­tems. We use robust and approved com­po­nents from our elec­tric motor mod­u­lar sys­tem kit, which we can quick­ly adapt to the require­ments of our customers.

Our ser­vices:

  • Draw­ings of rotor, sta­tor and magnets
  • Con­struc­tion of the motor housing
  • Cre­ation of assem­bly drawings
  • Con­struc­tion of shaft and bear­ing system
  • Con­struc­tion of the wind­ing insu­la­tion system
  • Prepa­ra­tion of parts lists
  • Con­struc­tion of the cool­ing system
  • Solu­tions for con­tact­ing windings
  • Mechan­i­cal strength of motor housings
  • Selec­tion and design of the rotor posi­tion­ing system
  • Selec­tion and posi­tion­ing of tem­per­a­ture sensors
  • Solu­tion for mount­ing of magnets
  • Selec­tion of shaft and rotor connection
  • Con­struc­tion of hair­pin and con­cen­trat­ed windings
  • Selec­tion of wind­ing wire and elec­tri­cal sheet
  • Con­tact­ing sys­tem of motor and inverter

3. Manufacturing of Motors

We help you build up first pro­to­types fast and sim­ple. Of course, we also design pro­duc­tion process­es for series man­u­fac­tur­ing so that your motors can also be pro­duced in high vol­umes. To mon­i­tor the per­for­mance and qual­i­ty of elec­tric motor com­po­nents, we offer ready-made test­ing concepts.

Our ser­vices:

  • Build­ing up prototypes
  • Indus­tri­al­iza­tion and man­u­fac­tur­ing strategy
  • Plan­ning of pro­duc­tion processes
  • Qual­i­ty assur­ance of mag­nets and sheet metal
  • Con­cept for end-of-line testing
  • Plan­ning of motor test benches
  • Con­cept for bal­anc­ing of the rotor
  • Assem­bly con­cept for mag­nets and rotor
  • Elec­tri­cal test­ing of wound stator
  • Assem­bly con­cept shaft and rotor
  • Solu­tions for fix­a­tion of windings
  • Selec­tion of con­nec­tion tech­nol­o­gy of met­al sheets
  • Assem­bly process for wind­ing and insulation
  • Con­cept for recy­cling of cop­per and magnets
  • Selec­tion of sup­pli­ers and request for quotation
motor needle winder