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Electric Motor Production Solutions for Electric Motor Production

Editor: MA Alexander Stark

Gehring places its presence at this year's EMO Hannover under the motto “Technology Openness for reduced CO2 emissions and fuel consumption”

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With a complete solution for stator production, Gehring relies on technology and system know-how from a single source.
With a complete solution for stator production, Gehring relies on technology and system know-how from a single source.
(Source: Gehring)

Gehring, together with its specialized subsidiary copperING, has developed integrated production solutions for stators for the manufacture of electric motors. Automobile manufacturers and suppliers receive all relevant technologies as well as process and system design from a single source. The Gehring Group supplies fully automated, flexible production lines for stators that meet the quality requirements as well as the cycle times and flexibility requirements of the automotive industry.

At EMO Hannover, Gehring presents two new machines for the process chain: a robot-based station for placing the pins in the stator grooves and a laser machine for welding the wire ends.

Parallel to technological developments in e-mobility, existing vehicle models with combustion engines must be further optimized to comply with stricter emissions legislation. There are different approaches to reducing consumption and emissions. Two efficient methods come with the so-called nanohoning and formhoning from Gehring. This involves a process sequence for manufacturing engines with coated cylinder tracks (nanohoning) and a technology for compensating distortion in the engine (formhoning). Both processes are now used in the series production of combustion engines and achieve significant savings.

Manufacturing Engines with Coated Cylinder Tracks

The Gehring technology chain of nanohoning is used to manufacture engines with coated cylinder liners and comprises the process chain of roughening - thermal coating - honing. Thermal spray coatings in cylinder tracks of combustion engines increase the energy efficiency of the units by reducing friction. Wear and tear as well as the size of the motors are reduced. In addition to the honing processes, Gehring also supplies laser roughening for this process chain. Laser roughening enables high adhesive tensile strengths with low roughness. This means that less coating material is required. In addition, operating costs are reduced, since tooling costs are eliminated compared to other processes.

Gehring has introduced mold honing technology to further improve fuel consumption in conventional aluminum or cast-iron engines. The functional deformations of the cylinder are retained in the manufacturing process, achieving an almost ideal cylindrical geometry in the operating state. This has beneficial effects on CO2 emissions, oil and fuel consumption, performance and wear. Together with leading global automobile manufacturers, this technology has been implemented and is now creating cost advantages at plants in the USA, Europe and China. In series production, for example, friction in the cylinder bore was reduced by more than ten percent and emissions by approximately 1.5 grams of CO2 per kilometer. The costs of implementing the process are only a fraction of the costs of other measures with a comparable effect.

Complete Range of Honing Technology

Using the newly developed PT 600 two-spindle honing center, Gehring is presenting the complete range of honing technology for machines, automation, tools, cutting bars and contract manufacturing at EMO Hannover. Both in-line and V-engines can be machined on the PT 600. With its tool changer, comprehensive process capability, ergonomic loading concept and optimized footprint, it is suitable for flexible production of a wide variety of engines by suppliers and contract manufacturers.

Machine Premiere for Laser Structuring

As an expert for functional surfaces, Gehring offers not only products for honing, laser honing and laser roughening, but also laser structuring machines that increase static friction. The functional design of the surfaces can partly replace complex and expensive processes and components. At EMO Hannover, Gehring presents the new GLS 1000 live in Hanover. It can be used as a stand-alone solution or integrated into a production line. Gehring also considers itself a technology partner who develops applications together with the customer.

Premiere of the IoT Customer Platform Gehring Core

Another premiere of Gehring in Hanover will be the new IoT customer platform Gehring Core, which provides users with individually prepared data on their machines. This enables them to benefit from the advantages of predictive maintenance and transparent production, the company says. Specific production analysis and optimization measures are also possible. The user platform can be operated on the customer's network or as a cloud service.

This article was first published by MM MaschinenMarkt.

Original by Victoria Sonnenberg / Translation by Alexander Stark

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