Electric Motors and Internal Combustion Engines: Manufacturing Solutions for Complex Drive Components
EMAG offers the complete process chain for electric motor and internal combustion engine components: from rotor shafts and stator housings to pistons, injector bodies, and turbocharger shafts. Technology, automation, and process development all come from a single source - for cost-effective high-volume production with the highest precision.
From rotor shafts to pistons: Precision manufacturing for electric and combustion engines
Electric motor components: rotor shafts, stators, and gearboxes on fully automated lines
The growing importance of electrified drives requires cost-effective and reliable manufacturing concepts for key components in the e-mobility sector. EMAG develops fully automated production lines for rotor shafts, stator housings, as well as gear wheels and gear shafts. These solutions take into account different component variants, high requirements for dimensional accuracy and surface quality, and efficient process chains. Depending on the workpiece, machining processes include turning, gear cutting, ECM machining, and hard finishing. The goal is stable batch production with high productivity, reproducible quality, and optimally coordinated automation.
Internal combustion engine components: pistons, injector bodies, camshafts, and turbocharger shafts
Internal combustion engines place high demands on the dimensional accuracy, load-bearing capacity, and process reliability of key components. EMAG develops tailored manufacturing solutions for components such as pistons, injector bodies, assembled camshafts, and turbocharger shafts. Depending on the workpiece and the specific application, machining, electrochemical, or thermal processes are employed. The process chains are designed to enable stable batch production, reproducible quality, and cost-effective machining of sophisticated engine components.
Common denominator: Holistic process chains and a single point of contact
Whether electric motors or combustion engines - EMAG consistently follows the “One Face to the Customer” principle. An experienced contact person is responsible for the entire manufacturing solution: from design coordination and machine selection to link-up. This significantly reduces the coordination effort for our customers - while ensuring short delivery times and a quick start to production.
Advantages
- Complete process chains from a single source: Turning, welding, hardening, grinding, and ECM are optimally coordinated - without interface losses.
- High productivity through link-ups. Weight-optimized components for electric vehicles: Machined rotor shafts and ECM-machined hollow shafts specifically reduce component weight - for greater range.
- Highest precision: Grinding processes that integrate measurement and correction systems (closed loop) achieve reproducible, highest surface quality.
- Short retool and maintenance times: Modular machines with identical components and simple automation systems reduce downtime and operating costs.
- A single point of contact: EMAG handles the planning, delivery, and coordination of the entire manufacturing solution - including third-party machines and peripherals.
Questions and Answers
- What components for electric motors and internal combustion engines does EMAG machine?
- What are the specific manufacturing requirements for motor and drive components?
- Which EMAG technologies are used in the production of electric motor components?
- What does a typical process chain for a rotor shaft look like?
- Which EMAG machines are suitable for machining gear shafts and gear wheels?
- What quality and tolerances can be achieved when machining compressor rotors?
- In which industries are the motor components manufactured by EMAG used?
- How can cost-effectiveness be increased in the production of engine components?
EMAG offers machines and manufacturing systems for machining components for electric motors and internal combustion engines. The portfolio includes solutions for rotor shafts, stator housings, gear wheels, and shafts for electric drives, as well as for pistons, injector bodies, camshafts, and turbocharger shafts for internal combustion engines. EMAG provides the whole process chain - including automation - for every component.
Engine and drive components require tight tolerances, high surface finishes, and reliable repeatability - all while meeting high production volumes. Rotor shafts and turbocharger shafts are high-precision components that must function reliably under extreme operating conditions. Thin-walled housings place special demands on clamping strategies and process sequences.
For electric motor components, EMAG relies on a broad spectrum of technologies: turning, gear hobbing, grinding, laser welding, and electrochemical machining (ECM) for deburring and inner forming. All processes can be linked up in fully automated production lines.
A fully automated line for a two-piece rotor shaft comprises up to eleven operations: turning of the individual parts, laser cleaning, laser welding of the joint, hard external machining, internal machining, tooth profiles, and final grinding of the bearing seats and shaft surfaces. Link-up and automation are handled via TrackMotion, gantry loaders, and robots.
For gear shafts, EMAG recommends the VT 2 and VT 4 4-axis turning machines for turning, the HLC 150 H for gear hobbing, and the VTC 100 GT for hard finish machining. The CI 400 handles ECM machining of tooth profiles, while gear wheels are turned on the VL 3 DUO, gear hobbing is performed on the HLC 150 H, and internal grinding is carried out on the VLC 200 GT.
The G-H grinding machines from EMAG SU enable surface finishes in the micrometer range. Through the combined use of CBN rough-machining and ceramic finishing wheels in a single setup, as well as an integrated closed-loop measurement and correction system, the highest profile accuracies are reliably achieved. Profile deviations are automatically detected and corrected through re-dressing and finish grinding.
EMAG’s manufacturing solutions primarily target the automotive and commercial vehicle industries - for both electric vehicles and internal combustion engines. Additionally, applications in compressed air technology (compressor rotors), engine manufacturing for industrial and agricultural machinery, and the field of stationary electric motors are relevant. The solutions are designed for high-volume production, handling approximately 360,000 rotor shafts or up to 450,000 turbine rotors per year.
EMAG delivers cost-efficiency benefits through complete process chains from a single source: reduced setup times, optimized cycle times, and high machine availability through process segmentation. Simple automation, identical components, and a single point of contact minimize planning and maintenance efforts.
Workpieces
Cam
Composite camshaft (joining)
Precision manufacturing of camshafts places high demands on production. The thermal joining technique offered by EMAG combines flexibility with productivity: freedom in design and production processes…
Gear shaft (e-bikes)
Shaft machining is one of EMAG's core competencies. Our special 4-axis machines for shaft production are ideal when it comes to high-precision and highly productive machining of gear shafts. Turning,…
Gear wheels (e-bikes)
Regardless of whether they are made of plastic or metal, EMAG solutions can be used to manufacture a wide variety of gear wheels. Thanks to the wide range of technologies available at EMAG, we can…
Hollow Shaft (e-bikes)
For years, the hollow shaft has been established as the axle for the crank system in an eff ort to reduce weight.
However, due to the unique configuration of these workpieces, the traditional chip…
Injector body
For the production of injector bodies, EMAG offers turning centers for soft machining by chipping and electro-chemical machining centers for deburring or inner forming.
Piston
The machining of pistons is one of the most demanding processes in manufacturing engines and EMAG offers the whole process chain for their complete-machining. The outer contour, in particular, calls…
Rotor (e-bikes)
The rotor shaft is the central component of the electric motor and EMAG has already developed numerous solutions precisely for this important component. From turning to gear cutting to hard gear…
Rotor Shaft - Assembled (Electric Motor)
Rotor shafts in stationary electric motors are usually solid shafts with a smaller diameter. Alone, these rotor shafts are not heavy, however the small diameter of the shaft requires that a large…
Rotor shaft (electric motor)
Rotors for compressors
Finish machining of rotors for air compressors or rotary compressors is a high-tech task: The surfaces need to be perfect down to the last micrometer. The new G-H series from EMAG SU was developed…
Stator Housing
Our specialists have developed a highly efficient solution for the cutting machining of stator housings for electric motors.
Turbocharger Shaft
The production of turbocharger components is one of the most demanding tasks in automotive manufacturing, At EMAG, we deliver speed and precision with our complete production line solutions.
