Experience the latest machines and technologies for stators, hairpins, busbars and axial flux motors up close. Talk to experts from the industry! We look forward to presenting our innovative solutions to you and to answering all your questions.

Our Co-Exhibitors

WAFIOS

Machines for hairpins, busbars and axial flux coils

Machines for the production of hairpins and axial flux coils

CNC Bending machine FMU 40E: Live production of hairpins, inductor coils and continuous hairpins. In addition, there are new innovations that make the programming of hairpins even easier and faster.
SpeedFormer for a flexible serial production of hairpins, with many new technical features
iQplug&straight Operator assistance for initial adjustment of straightening devices using a straightness measuring device
HQ bending technique for hairpins: The new bending technology enables the production of even more compact winding heads while maintaining highest qualities

Machines for the production of busbars

iQconvert: The solution for converting STEP data into machine code. The tool facilitates the programming and control of our machines
BMF 60 with new unit for mechanical insulation stripping process.
Measuring and correcting busbars: Discover sophisticated measuring cells for measuring and correcting busbars

Gehring

Gehring stands for technologically innovative solutions, extensive expertise in production technology for the electric drivetrain and, last but not least, many decades as a system supplier to OEM and TIER1 customers within the automotive industry and supplier industry.

The integrated portfolio includes production technology for the series production of traction drives in electrified vehicles based on hairpin technology.

Due to shorter product life cycles, the focus of production here is on higher productivity and better capacity utilization with greater flexibility of the systems.

In the run-up to production, the engines are therefore run freely in our technology center on original equipment that is close to series production, so that the transformation to the series production process can be implemented more quickly. Of course, production is subject to strict quality controls after each work step. To this end, we are equipped with the necessary measuring technologies and testing procedures to ensure complete documentation.

The Technology Center also develops and builds sample stators and prototypes; the future goal here is to achieve short throughput times and reduce production costs. Nevertheless, some of the process experience can also be transformed here later for series application.

The following processes are among our core competencies:

Basket setting
Widening
Twisting
Cutting
Laser welding
Impregnating
Powder coating
Measuring stators

Visit us and find out more about our innovative solutions for the future of mobility.

Friedrich-Alexander-Universität Erlangen-Nürnberg, Lehrstuhl FAPS

The Institute for Factory Automation and Production Systems (FAPS) at Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU) focuses on the development of innovative manufacturing processes for mechatronic products.

The associated research group for electric machine production focuses on manufacturing processes for electric motors and contactless charging systems. From process development and optimization to recycling, the topic area of electric machine production is covered in a fully comprehensive, future-oriented and sustainable manner. The main areas of research are

Development and optimization of production technologies and processes

Development and optimization of production technologies and processes
Innovative materials
Digitization and data-driven solutions
Process automation
Recycling and circular economy
Process simulation

Karlsruhe Institute of Technology (KIT)

Production Science for Electromobility

The wbk Institute of Production Engineering at the Karlsruhe Institute of Technology (KIT) is developing innovative manufacturing and assembly processes for electric traction motors together with its industrial research partners. Beyond the further optimization of efficiency and power density, the research work addresses in particular the shortening of time-to-market and the reduction of production costs.

The focus of the trade show participation is on flexible production technologies for stators and rotors as well as digital process chains for efficient tool design and intelligent process parameterization:

Kinematic manufacturing and assembly processes for fast and flexible prototyping,
Process models for shaping hairpin plug-in coils as well as insertion, twisting and laser-based contacting of stators with hairpin winding.

RWTH Aachen – PEM

The Chair "Production Engineering of E-Mobility Components" (PEM)

… at RWTH Aachen University was founded in 2014 by "StreetScooter" co-founder Professor Achim Kampker. In ten research groups, the team is dedicated to all aspects of the development, production and recycling of battery systems and their components as well as the fuel cell and the production of the electric drive train and entire vehicle concepts. The research group "Electric Drive Production" contributes to the economic, variant-flexible, future-oriented and sustainable production of the electric drive and its active components (rotor and stator). The focus is on investigating issues along the entire value chain - from the semi-finished product to the finished drivetrain and from the individual process to the holistic consideration of cross-process interactions. In accordance with the PEM philosophy of the "Innovation Chain", the team works on new and innovative technologies, always keeping an eye on the path to industrial application and solution scaling. Current topics of the research group are:

Interdependencies between semi-finished product and process in stator production (with special focus on stripping, bending & welding).
Development and implementation of application-oriented test and inspection procedures as a basis for demand-oriented products and processes
Lifecycle-oriented optimization of production processes and development of measures to identify and reduce the CO2 footprint along the entire value chain
Use of AI-based methods for efficient, economical and sustainable electric motor production

Additive Drives

World leader in 3D printed electric motors

Fastest prototyping: we use innovative manufacturing processes to produce prototypes of new electric motors in as little as 4 weeks.

Unmatched efficiency: advanced designs enable a new and more sustainable generation of electric drives

Highest performance: With even more compact winding heads and state-of-the-art oil cooling, we achieve the highest power densities of 25 kW/kg - or 90 kW/l.

Customised electric drives: We develop customised electric motors, we find the ideal solution for every application - from 1 piece!

ElringKlinger AG

Expertise for change

A wide range of ElringKlinger components relating to e-motors, transmissions and inverters can be used in an electric drive unit. The design and materials of all our product solutions are tailored precisely to the relevant requirements – for maximum design freedom and functional reliability.
ElringKlinger supplies rotor/stator laminated stacks MetaloBond™, metal elastomer and MetaloSeal™ gaskets, radial shaft seals and housing covers for electric drive units.

MetaloBond™ rotor/stator laminated stacks
With the unique bonding technology of ElringKlinger, a permanent sealing function can be guaranteed for the stacks, so cooling channels can be implemented – especially for applications in directly cooled electric motors. MetaloBond™ stacks additionally provide a high mechanical stiffness.

Characteristics:

Sealing function of the stack due to special bonding agent
Insulating between layers and thus increasing efficiency in the application
Mechanical stiffness in the system to optimize NHV behavior
Multilayer stamping process for commercial advantages

Hexagon

Smart solutions for eMobility manufacturing

eMobility production has quickly grown to become a key area of modern automotive manufacturing. Hexagon has the ground-breaking metrology and automation expertise needed to understand and deliver solutions to the challenges of e-motors production.

BendingStudio XT software for all manufacturing steps starting with CAD file over the production of a master parts up to the production of serial parts incl. automated feedback to CNC bending machines
TubeInspect P8.2 HRC | P16.2 HRC: Camera-based tube measurement cells for efficient automated quality control of hairpin, busbar, and bent tubes e.g. for hydrogen piping systems
Portable measuring arms with 3D laser scanner for unmatched speed and flexibility in tube and wire measurement
High-accuracy CMMs with a 3D laser scanner or optical point sensor to create a complete digital representation of hairpins or to measure defined geometrical features of it

HPW Metallwerk GmbH

HPW is a leading manufacturer of winding wires for e-mobility and wind power and is thus one of the key companies in a rapidly growing future market.

As a specialist for PAI and PEEK-insulated copper flat wires, HPW has been a series supplier to numerous renowned European OEMs and Tier 1 manufacturers for several years with three production sites in Austria. A plant in North America for PEEK-insulated copper flat wires is currently under construction and will serve the first large-scale production in the USA from 2025.

As a technology leader, HPW manufactures PA12-insulated busbars with conductor cross-sections of up to 400 mm². The fully automated process covers the entire value-added chain from the raw material made of copper or aluminium to the finished insulated flat conductor. Aluminium busbars in particular meet the increasing demands of automotive customers for weight reduction, tight bending radii and temperature resistance of the insulation.

Hyperdrives

Benchmark electric drive systems

Hyperdrives specializes in the development and production of electric drive systems that are cooled by hollow conductors. These types of electric drives feature a very high continuous power density and efficiency at really low costs.

Drive systems cooled by hollow conductors and integrated SiC power electronics
Continuous power density of >8kW/kg (incl. SiC inverter)
Maximum efficiency in the partial load range
Established radial flow design with distributed windings which can be used in all rotor topologies (also without any rare earth magnets, e.g. separately excited rotors)
Production processes which can be industrialized and integrated into existing production landscapes
Solely standard automotive materials and components

Standard-Metallwerke GmbH

Standard-Metallwerke GmbH (Werl/Germany) - with approx. 450 employees - has been recognised as a reliable partner for precision tubes and fluid line components for more than 100 years. We are established on the market in the automotive industry and other industrial sectors with our semi-finished products, components and rigid busbars. Specialized in the materials aluminium and copper, we also provide products made of steel, stainless steel and composite materials.

Our coating know-how has been perfected over a quarter of a century and allows us to apply various insulation materials to a wide variety of materials by means of extrusion according to customer requirements. In addition to electrical isolation and corresponding mechanical resistance, this also ensures optimum surface protection against aggressive media and abrasion. The special process achieves a strong adhesion of the coating to the conductor material, which enables bending without wrinkling or tearing of the respective coatings with voltage loads of up to 1,000 V.

Core materials: aluminum, copper, cupal
Coating materials: PA12, PEEK, PPS, XLPE
Dimensional range: up to 80 mm x 8 mm
Coating thickness: 100 – 1200 µm

Based on our experience in coating technology, we are the pioneers in the field of extruded busbars, which are supplied on coils for further processing. However, we can also provide busbars that have already undergone further processing, which includes cutting to fixed length, end stripping and bending, for example.

Whether as a material supplier or manufacturer of complete system components - we are at your side as a reliable partner with our expertise, from development to series delivery!

Our association within the Wilms Group offers decisive advantages.

E-Mobility Sales

Your contact person

Martin Bauer

Manager - Technical Sales, E-Mobility

+49 7121 146-219

ma.bauer@~@wafios.de