Influences of Joining Process Parameters on Stator and Rotor Cores for Electric Drives

Due to the rising demand for high-efficiency electric drives, the requirements for production processes are also increasing. The process steps have a significant effect on product quality and efficiency of the electric machine. In this paper, the joining processes for stator and rotor lamination stacks i. e., interlocking, laser welding, bonding and bonding varnish are compared in a holistic evaluation process. For this purpose, practical joining tests with varying process parameters on basis of a toroidal core are carried out. In this context, the process behavior and energy demand during manufacturing are evaluated. Mechanical and electromagnetic tests are used to determine the influence of the joining parameters on product quality and electromagnetic losses. The investigations were intended to support the later development of new complex processes for electric drives.