Engineering & Innovation

We will support you, from the development of prototypes to mass production. Our broad network of contacts and sector expertise enables us to produce the optimum solution for your orders, using the very latest tooling. Our customers describe us as a technological leader.

For us, this means that we:

  • act as an innovative development partner and an interface between customers and suppliers
  • have the world’s most up-to-date laser systems in productive operation
  • view our service holistically, beyond laser cutting alone
  • react very quickly at all process stages
  • are used to handling sensitive information

We believe that our strengths include individual, project-specific advice and support in order to achieve the best possible solution to meet our customer’s requirements. We will contact you at an early stage should any potential production problems arise, and work out appropriate solutions or alternatives – which we regard as good service. It seems natural to us that we should point you towards any potential opportunities or improvements. We also check the way the project is implemented with regards to its suitability for mass production at a later stage, and for the generation of components that are close to production.

All the insights and information we acquire in connection with any project will be made available to the customer when that project ends.

3D-Slice technology

We can use the example of a large segmented stator to illustrate an innovation by LCD LaserCut AG.
The winding slots on the internal diameter of the lamination stack are angled, for electrical reasons. The mechanical guide slots (e.g. swallow tails) on the outer rim of the lamination stack are straight.
Each lamination therefore has a different geometry and is a unique item – a situation that is ideally suited to the flexibility of laser production. LCD Slice Software is used to program the laser, and the lamination stack is produced in one continuous process.

Method
A 3D solid is created for the stator, rotor or segment stack. The length of the iron core is cut into slices (laminations), according to the thickness of the material. The laminations (each with its own independent geometry) are cut by a laser and then layered into a stack shape in the normal way. This lamination stack can be secured by the usual methods, e.g. welding, bonding, screwing, riveting, etc.   

 

Benefits

  • Slice technology is particularly appropriate for the prototype stage of electric motor development.
  • The slicing process produces the optimum structure for the motor in one process step.

 

 

Link von Video auf Youtube produced by PB

Stator external diameter: 1,800mm
Segmented structure
Inner slots are angled, outer guide slots are straight
Each individual lamination is unique!
Executed with LCD Slice Software.

Form fit

The profiled bore was developed to simplify the join between two components, e.g. joining a shaft and a rotor.

The required characteristics are achieved by the specific displacement of geometrical elements in the vicinity of the join (low insertion force, high torque, variable contact ratio).

This type of connection enables different components to be joined together easily and without any thermal effects. At the mass production stage, this produces major advantages in comparison with conventional jointing techniques and can frequently be used to resolve problems.

 

Benefits

  • We carry out the mechanical design of the entire profiled bore
  • We verify the profiled bore by manufacturing test dummies, ensuring tolerances and carrying out series of torque measurements
  • We have a force/displacement press specifically designed to provide a graphic record of the absorption of the insertion forces
  • The rotor stacks are cold pressed (joined) onto the shaft
  • As a result of the profiled bore, high torques can be delivered reliably without any additional re-working of the shaft.

Rotor stacks are cold pressed (joined) onto the shaft

 

Segmentpaket aus 90° Segmenten, aufgebaut im Brickwall-Prinzip

Segment and tooth stacks

Segmentation of large rotor and stator laminations involves the division of the 360° slice of steel sheet into a number of separate segments. The angle may be variable, but this is determined by the geometry. The potential for segmentation will be defined between the customer and LCD in advance. During the stacking process, the segments are stacked on top of each other in a “brick wall” formation. This then produces the required rotor or stator in the form of a single component once the bonding process has been carried out.
This process makes it possible for large components to be manufactured with small laser machines or automatic punching presses.

Another option is to divide stators into single tooth segments. The development of single tooth stacks makes the winding process easier, while also enabling the copper ratio to be increased in each tooth stack. The individual stacks are connected together through a coupling (as depicted below) to form the stator.
The appropriate coupling will be specified in accordance with the requirements.

 

Benefits

  • Segmenting (i.e. dividing components into multiple elements) gives the developer the opportunity to construct individual parts so that any post-processing tasks become easier.
  • The partial segments can be joined together easily at the required time to form the finished assembly.
  • Material utilisation is improved many times over, depending on the component involved.
  • An injection moulding machine can be used to insulate the winding space.

A selection of the various tooth connections is shown above. The cost of joining the individual tooth stacks together may be reduced, depending on which connection option you use. The advantage of the axial method is that it improves the stack structure, which results in a higher level of precision. LCD LaserCut AG will be very happy to help you specify the connection. We are also able to carry out various tests. You will receive the test results (joint strengths, torque, etc.) in digital format, which may be enormously important when it comes to the mass production stage.