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Analysis of Connection Geometries for Segmented Stator Cores Machined with Laser Beam Cutting

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Abstract:

Current developments in the transition to renewable energy and the electrification of mobility are leading to higher demands with regard to resource efficiency in the production of electric motors. One current trend is the segmentation of the stator pack, which enables higher material utilization and novel assembly processes. In this paper, different connection geometries for individually stacked stator segments are examined. Experiments were conducted by laser beam cutting and stacking of samples with different segmentations and connection geometries. Afterwards the geometric dimension and tolerances are compared with an unsegmented stator. Furthermore, the impact of the additional connection on the mechanical behavior under load are investigated using Finite Element Analysis. The required force to join segments across different connection geometries ranges from 462 N to 1875 N, while the cylindricity of segmented stator cores spans from 33 µm to 59 µm, compared to 40 µm for the unsegmented sample. Simulation results show that the elastic strain on the connections is largely influenced by the size of air gaps between segments, as well as the geometry and number of segments.

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Periodical:

Materials Science Forum (Volume 1187)

Pages:

55-62

DOI:

https://doi.org/10.4028/p-3Tuj2F

Citation:

Cite this paper

Online since:

April 2026

Authors:

Florian Hoffmann*, Philipp Plänitz, Alexander May, Florian Winkler, Markus Barth, Sören Majcherek, Matthias Hackert-Oschätzchen

Keywords:

Electric Motor, Non-Conventional Manufacturing, Stator Segmentation

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Creative Commons CC BY 4.0

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* - Corresponding Author

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