The solution for efficient stator machining – developed in partnership with MAPAL

E‑mobility is rede­fi­ning the requi­re­ments for manu­fac­tu­ring tech­no­lo­gies in the auto­mo­tive indus­try. In par­ti­cu­lar, the cost-effi­ci­ent machi­ning of thin-wal­led alu­mi­num sta­tor housings for elec­tric dri­ves demands relia­ble and highly pro­duc­tive solu­ti­ons. Tog­e­ther with too­ling spe­cia­list MAPAL and our sub­si­diary brand RASOMA, we have deve­lo­ped a pro­duc­tion-ready machi­ning pro­cess that sets new bench­marks in pre­cis­ion, cycle time, and quality.

Perfectly coordinated overall concept

At the heart of this deve­lo­p­ment is the RASOMA DZS 400–2, also known as the “Sta­tor­ma­ker”, a ver­ti­cal machi­ning cen­ter spe­ci­ally desi­gned for sta­tor pro­ces­sing. Based on the modu­lar ver­ti­cal machi­ning plat­form from our sub­si­diary RASOMA, the machine was fur­ther deve­lo­ped spe­ci­fi­cally to meet the requi­re­ments of high-volume pro­duc­tion of thin-wal­led alu­mi­num com­pon­ents. Two work­piece spind­les enable com­plete machi­ning of the part in just two clam­ping ope­ra­ti­ons – after the pick-up and first machi­ning step, the second spindle simul­ta­neously car­ries out the finis­hing ope­ra­tion on the next workpiece.

Thanks to the trans­fer prin­ci­ple with pick-up and drop-down hand­ling and its com­pact design (foot­print approx. 7.5 × 2.6 m), the machine can be seam­lessly inte­gra­ted into exis­ting pro­duc­tion lines. The high degree of auto­ma­tion – optio­nally with robots or con­veyor sys­tems – ensu­res maxi­mum pro­duc­ti­vity with mini­mal non-pro­duc­tive time.

Innovative tool technology for maximum precision

The spe­ci­ally deve­lo­ped too­ling con­cept from MAPAL is a key com­po­nent of the pro­cess. The inner and outer con­tours of the sta­tor housing are machi­ned simul­ta­neously using coun­ter-rota­ting tools: while the work­piece rota­tes, the exter­nal machi­ning tool remains sta­tio­nary. This mini­mi­zes vibra­ti­ons and signi­fi­cantly impro­ves pre­cis­ion. The dif­fe­rence in tool rota­tio­nal speeds ensu­res uni­form cut­ting speeds on both the inner and outer diameters.

This allows even thin-wal­led com­pon­ents to be machi­ned relia­bly wit­hout the need for ela­bo­rate dam­ping solu­ti­ons. Thanks to high cut­ting speeds and per­fectly coor­di­na­ted tool change stra­te­gies, the pro­cess achie­ves excep­tio­nal pro­cess relia­bi­lity – even when machi­ning cri­ti­cal fea­tures such as cylind­ri­city, con­cen­tri­city, and diameter.

Proven in series production

The com­bi­na­tion of a highly dyna­mic machine con­cept and relia­ble too­ling tech­no­logy also pro­ves its worth on an indus­trial scale: at LTH Cas­tings – a lea­ding sup­plier to the auto­mo­tive indus­try – the pro­cess has alre­ady been suc­cessfully inte­gra­ted into series pro­duc­tion. Ope­ra­ting in three shifts, up to 180,000 sta­tor housings are manu­fac­tu­red there each year – with out­stan­ding qua­lity and mini­mal scrap rates.

Thanks to fle­xi­ble tool chan­geo­ver, the machine can also be adapted to dif­fe­rent part geo­me­tries and com­plex con­tours. This pro­vi­des the neces­sary fle­xi­bi­lity to meet future demands of e‑mobility as well.

Benchmark for e‑mobility

With the RASOMA DZS 400–2, its uni­que pro­duc­tion pro­cess, and the per­fectly matched too­ling tech­no­logy from MAPAL, we offer a glo­bally lea­ding eco­no­mic and tech­no­lo­gi­cal solu­tion for machi­ning sta­tor housings in e‑mobility. As a trus­ted part­ner to the auto­mo­tive sup­ply indus­try, we con­tri­bute to effi­ci­ent and future-ready manu­fac­tu­ring pro­ces­ses – pre­cise, relia­ble, and desi­gned to meet the hig­hest demands.