Our prototyping department is the central development partner for prototypes and very small production runs of traction drives for electrified vehicles based on hairpin technology. We design and assemble all mechanical components of the stator and monitor every step of the process with comprehensive quality controls. State-of-the-art measurement and testing methods ensure that all components and assemblies meet the highest standards.
We place a special emphasis on the development and optimization of the winding head design, which is critical to the performance, form factor, and efficiency of modern electric motors. By manufacturing A and C prototypes on production equipment that closely resembles that used in series production, we validate not only the product design but also the underlying manufacturing processes under realistic conditions, so that you can move directly from prototyping to series production with us.
From concept to production
We are your solution partner throughout the entire value chain —from the initial idea to mass production. Starting with the design phase, we support you in developing optimal hairpin concepts. In our prototyping department, we produce A and C samples quickly and reliably to validate concepts at an early stage.
In addition, we offer flexible solutions ranging from individual machines to small-batch production and fully automated mass production. We combine technological expertise with practical implementation. This ensures that your products not only function as intended but can also be manufactured efficiently and cost-effectively —all from a single source, tailored to your requirements.
Sample production
Sample production
Measurement and inspection of stators using various testing methods
Winding Designer – Efficient Modeling of Winding Designs
We develop hairpin, I-pin, and X-pin windings from start to finish. You’ll receive the finished design, including all available data. Here’s how we make it possible: We determine the winding topology while taking your manufacturing constraints into account. The model runs so quickly that your design question is answered even as you’re asking it.
Precision redefined with the Gehring Inspection System
The Gehring Inspection System (GIS) enables precise measurements as a stand-alone or inline solution, from prototype production through to mass production. Through fast inspection processes, comparison with models or golden samples, and targeted feature extraction, relevant manufacturing characteristics for every production step in stator manufacturing are identified early, allowing processes to be efficiently optimized.
Transparent pin evaluation with Gehring Pin Studio Online for maximum quality and process reliability.
Ultra Short / Mini Pin and X-Pin
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Special Features:
If you are looking for a reliable partner for your stator manufacturing projects, then you have come to the right place. We look forward to working with you. Contact us today to learn more.
Contact
Sales E-Mobility
+49 711 / 3405-0
sales.eu@gehring-group.com
