• The rotor shafts for electric motors are produced completely on EMAG machines.
    Rotor shaft (electric motor)
  • Articulated cage—produced on an EMAG vertical turning center VTC 100-4
    Articulated cage
  • PECM for the machining of blisks
    Blisk
  • Brake disc
  • Cam
  • Composite camshaft for a small engine
    Composite camshaft (joining)
  • Automobile crankshaft machined on the PM 2 series.
    Crankshaft (automobile)
  • Crankshaft (for small engines)
  • CV joints make high demands on the machining technology. Core components: Kingpins, articulated cage, joint ball
    CV Joints
  • Dies
  • Differential pinion—precision machining on VL machines
    Differential pinion
  • Differential housing
  • Distributor flange
  • Feed screw
  • Flange manufactured on VL 2 lathes
    Flange
  • Gears are machined on EMAG VL series machines
    Gear
  • Gear shaft
  • Composite gear shaft manufactured with high precision by the use of EMAG heat shrink assembly technology.
    Gear shaft (joining)
  • Gear shaft (laser welding)
  • Gear with synchronising wheel
  • Gear of an automobile gearbox manufactured on a VLC 200 H
    Hobbing gears
  • Injector body
  • Machines by the EMAG Group for Kingpin production
    Kingpins
  • Master brake cylinder
  • To machine pistons with precision poses a particular challenge for all manufacturing solutions
    Piston
  • Pump ring production on the high-precision SK 204 grinder
    Pump ring
  • Railway wheel manufactured with precision on VLC 1200 turning centers
    Railway wheel
  • Roll rings are precision components
    Roll ring
  • Screw
  • Sprocket
  • Sprocket (Manufacturing System)
  • Steering pinions can be machined with great precision on the EMAG VT machine
    Steering pinions
  • Triple-sector clutch
  • Surface layer hardening an armature shaft on an eldec MIND 750
    Armature shaft
  • Input shaft
  • Balance shaft
  • Induction hardening through precision control
    Hydraulic Valve
  • Camshaft
  • Hardening shifter shafts with induction hardening
    Shifter Shaft
  • Surface layer hardening with the eldec hardening machine
    Wheel Hub
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EMAG Manufacturing System for Electric Motor Shafts

Production line for rotor shafts for electromobility applications

Rotor shafts in stationary electric motors are usually solid shafts with a low diameter. By themselves, these rotor shafts are not heavy. However, the low diameter of the shaft requires the use of a large rotor plate package, which makes the overall rotor quite heavy. For stationary motors, this is not a problem. However, in motors for electric vehicles, every little bit of extra weight reduces the vehicle’s range.

With the production line presented here, EMAG demonstrates how weight-optimized rotor shafts – and weigh-optimized electric motors in general – can be mass produced for state-of-the-art electromobility concepts.



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Assembled rotor shafts for weight-optimized electric motors

Some years ago, the automotive industry began to forgo the production of certain components as a single part, e.g. by forging, in favor of using assemblies in an effort to reduce weight.
A relatively well-known example is the cam shaft, which was traditionally made from a forged raw part. Today, the individual cams are joined to a central pipe by heat-shrinking (see here: EXAMPLE WEBSITE). In the advanced version, the cam shafts are replaced with individual cam parts.
However, the basic idea remains the same: Reduction to essentials.

The same concept is applied to the assembly of rotor shafts.

How can the plate package of a rotor be reduced to a minimum without losing the weight advantage to an increased diameter of the rotor shaft?


The answer is a hollow, assembled rotor shaft. Besides significantly reduced weight, this design offers several other benefits. The production process for the rotor shaft can be broken down into several short partial processes, which reduces the overall cycle time and increases the potential for large output quantities. Furthermore, the shaft geometry can be matched perfectly to motor power and the configuration of the power train components – another advantage.

EMAG is already offering a suitable complete solution for the production of such rotor shafts. It includes VL and VT-series turning centers, ELC laser welding machines, MIND-series induction hardening machines, as well as VTC and DS-series grinding machines.

Rotor shaft for electric in 47 seconds

As the video above shows, EMAG breaks the production of a rotor shaft down into 11 operations that are all realized on EMAG machines (apart from the cleaning process).

In OP 10 and OP 20, the two sides (inside and outside) of the welded raw parts are machined.
This is followed by a cleaning process and the joining of the two parts to form a rotor shaft by laser welding in OP 40.

The hardening of the bearing seats in OP 50 is also done as part of the line cycle, taking only seconds on a MIND hardening machine.

This is followed by finishing the outside of the electric motor shaft in OP 60 on VT machines. The machining operation of 4 axes is not only extremely fast, but also powerful enough for hard machining.
Similar to the final outside machining of the shaft, the final interior geometry is created on VL-series turning centers in OP 70.

OP 80 and OP 90 were designed with flexible configuration options of the rotor shaft line in mind. Gearing and final contours can be created in this step as required.

In OP 100, a perfect surface finish is created on the VTC-series vertical shaft grinding machine. After this process and the subsequent cleaning, the shaft is ready for joining with the plate package.

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Advantages

    • Technology, automation, and process development all come from a single source. In the end, you will benefit from a complete solution, with guaranteed short lead times and a timely production start.
    • We optimize the interaction between manufacturing systems, peripheral machines, and automation.
    • The overall system developed by EMAG benefits from lean automation systems, optimized interfaces, and short routes. This ensure a timely start-up and a long-term cost-effective total process.
    • The machines use many common, identical parts. The production system also stands out for its short re-tooling and maintenance times.
    • A contact at EMAG is in charge of project execution and supports your planning with his experience and system expertise.
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