The machine builders Gehring and Wafios develop and manufacture turnkey production lines for hairpin stators for the global automotive industry. Gehring stands for extensive know-how in the manufacture of the electric drive train. The integrated portfolio includes production technology for manufacturing traction drives in electrified vehicles. WAFIOS completes the portfolio with the manufacturing process of forming technology. WAFIOS supplies the bending technology for the complex hairpin and I-pin geometries. Both companies will present their latest products in this field at CWIEME 2023.
Partner Lambda Resins contributes Lampdapox, a potting material that fills all cavities in a ready-to-install stator where air would otherwise be found. The potting ensures rapid heat transfer from the winding to the cooling jacket. Whether a stator consists of hair pins or a conventional wire winding is irrelevant. The potting reliably protects the motor from overheating. The motor can either be operated at a higher power or be dimensioned smaller from the outset to save costs.
Lambda Resins offers Lambdapox with thermal conductivities ranging from 2 to 8 W/mK, depending on the requirement or the amount of heat to be dissipated. This is about 100 to 400 times the value of air. Compared to liquid cooling media such as oil, the solid potting material has a number of advantages: No lines or pumps are required, there is no risk of leakage, and there is no additional handling or maintenance effort.
For the trade fair appearance at CWIEME 2023, the managing director of Lambda Resins Uwe Köhler has specially designed a test bench with two identical electric motors. But there is a difference: one of the motors was cast with Lampdapox 8 (8 W/mK). A hydraulic pump serves as a brake or load to bring both units to their performance limits. “We pick up the operating temperatures of the engines and display them graphically on the monitor together with the performance data. The viewer can see exactly what difference the Lampdapox encapsulation makes in operation when we increase the load, for example,” explains Uwe Köhler. The expert reveals in advance: “We’ve already had the case where an engine with our potting achieved twice the power output than one without potting.”
Gehring, WAFIOS and Lambda Resins at CWIEME 2023: Hall 3.2, Booth 32A14-B15
