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Efficient Machining of Stator Housings for E‑Mobility

Newly-developed, patented process for efficient simultaneous machining of stator housings (inner housing) for E‑Mobility

  • Semi-finis­hing up to 8 times faster 
  • Effi­ci­ency incre­ase of up to 100 % com­pa­red to con­ven­tio­nal tur­ning process 
  • Com­pact Machine Moun­ting due to Ver­ti­cal Machining

Innovation

Innovation

  • Serial pro­duc­tion solu­tion for effi­ci­ent ID and OD machi­ning of pot-shaped sta­tor housings by means of a simul­ta­ne­ous tur­ning process
  • Sub­sti­tu­tion of sepa­rate OD tur­ning pro­ces­ses (roughing) by an inte­gra­ted pro­cess of ID and OD machining
  • Signi­fi­cant reduc­tion in machi­ning time
  • Incre­ase in eco­no­mic efficiency

Workpiece

  • Pot-shaped sta­tor housings of e‑mobility with inner and outer contour
  • High requi­re­ments for form and posi­tion tolerances 
    • Fit tole­ran­ces IT6
    • Cylin­der shapes bet­ween 20 and 30 µm
  • High requi­re­ments for con­centri­city up to 0.05mm

Process Setup

  • Multi-spindle tur­ning cen­ter with tool turret
  • Ver­ti­cal test setup

Expan­sion sta­ges for serial production:

  • Inte­gra­tion of fur­ther machi­ning units through modu­lar design
  • Auto­ma­tic loading and unloading of work­pie­ces via pick-up
  • Inte­gra­tion of in-pro­cess mea­su­ring equipment
inner housing
cooling jacket
coolin sleeve
motor housing

Simultaneously Semi-Finish-Machining

  • Use of spe­cial inter­nal boring tools and self-deve­lo­ped exter­nal bell tools, which enable machi­ning of the inner and outer con­tour in parallel
  • Vibra­tion-dam­ped machi­ning on the thin-wal­led work­piece through simul­ta­ne­ous ope­ra­tion of the inner and outer tools
  • Simul­ta­ne­ous rotary move­ment of work­piece and inner tool with sta­tio­nary outer tool
  • Up to 8 times fas­ter machi­ning for the inter­nal and exter­nal roughing pro­ces­ses due to simul­ta­ne­ous machi­ning and hig­her num­ber of cut­ting edges (4‑fold cut­ting edges)
  • Lower tor­que on the clam­ping device due to coun­ter-rota­ting cut­ting for­ces of inter­nal and exter­nal machi­ning (com­pa­red to sin­gle inter­nal machining)
  • Auto­ma­ted parts hand­ling (pick-up)
  • Redu­ced re-clam­ping processes

Benefits

  • Simul­ta­ne­ous ID and OD machi­ning of pot-shaped sta­tor housings
  • Sub­sti­tu­tion of sepa­rate OD machi­ning pro­ces­ses (roughing)
  • Reduc­tion of cycle time: Semi-finis­hing up to 8 times fas­ter com­pa­red to con­ven­tio­nal tur­ning processes
  • Less re-clam­ping operations
  • Effi­ci­ency incre­ase of up to 100 % compa­red to con­ven­tio­nal tur­ning process
  • Incre­ase in eco­no­mic efficiency
  • Reduc­tion of vibra­ti­ons in the process

Other Fields of Application

  • Work­piece spec­trum with tube and pot-shaped geo­me­try e.g.
    • E‑mobility sta­tor housings
    • Alu­mi­num castings
    • Heat sinks for hybrid engines
    • Tube-flange cou­plings for the oil and gas industry
    • Bea­ring and housing com­pon­ents for gene­ral mecha­ni­cal engineering
    • Work­pie­ces for the plastics industry

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Contact

Sales Depart­ment
+ 49 371 802 – 333
sales.nsi@nshgroup.com
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