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Development of new materials, tools and technologies for depositing of thin polymer coatings on the em stator

The project refers to the development of thermoplastics isolation material for stator package of electromotor for achieve better electromotor efficiency and whole automatisation of the serial production process. This product is designed for automotive industry.

The main purpose of the proposed R&D project is to develop new polymer insulation material, new moulding tool togeter with an appropriate hard coating material, as well as new technology and automated production process for production of moulded metal-plastic electromotor (EM) stator package with a minimum thickness of insulation layer on the stator package. New moulded EM stator package will enable optimal caharacteristics of the EM with higher power, better efficiency with less energy consumption etc., which is very important for the use of such EMs in an automobile industry. The present production of moulded stator packages consists of lamellar package enclosed by insulating material between the package and the copper wire, winded around the stator package. Usually for the insulation material the insulation paper is used, however it doesn't satisfy the insulation demands by the automobile industry, because the EM with the paper insulation on the stator package enables worse working characteristics like power, efficiency etc. In addition, the insertion of insulation paper in stator package is done by hand, which means a high probability of human error, the production process lasts longer and is more expensive. With such insulation also the working reliabiltiy of the EM is not good enough. Besides the paper insulation, inserted around the EM stator, there is also a thermoplastic insulation, which has previously been injection molded and is subsequently inserted in the stator pack. Such a way of insulating the stator package differs from paper-based performance only in the changing the insulating material, while the insertion of insulation in the stator package is still done manual and thickness of the insulating layer on the stator package for the automotive industry is unacceptable. The third possibiltiy to produce the EM stator package with injection moulding of the insulation polymer material directly on the lamelar stator package. The goal of this project is therefore to find new materials, tools and injection as well as production technology to enable very thin (0,4 to 0,7 mm) layer of an insulation material on the EM stator package by directly injection molding of the polymer material with excellent insulation properties on the metal part of the lamellar stator package. In an automobile, electromotors can be found in many places such as the ignition, windows, side mirrors, rear lights and wipers, seat movements etc. The emergence of hybrid cars even widened their use and at the same time raised the rqirements about the characteristics of elctromotors, like higher power at smaller mass of the EM, better efficiency, lower energy consuption of the EM stc. During the development of the new thin polymer isolated stator package a number of requirements we have to be met from our side to achieve the reqirements of the automobile industry. In the automotive industry, the stator packages with injection molded thermoplastic insulation can already be found, but the problem lies in the stator pack insulation layer thickness, which is still too thick. Automotive industry requires thinner thickness of the thermoplastic insulation, mainly due to the reduction of production costs, increased productivity of manufacturing processes, improved efficiency and effectiveness of the electromotor etc. The existing packages have thermoplastic insulation thickness between 0.9 mm and 1.1 mm. Our main project objective will be to achieve a thickness of thermoplastic insulation on the stator package between 0.4 mm and 0.7 mm and to find the minimum thickness of the thermoplastic insulation that is yet to be achieved by thermoplastic injection molding process without risks of electrical breakthrough, of the penetration of an insulating layer inside the EM stc. Therefore an optimal flow conditions of the insulation material during the injection process will have to be achieved. To achieve the desired thickness of the insulating layer (between 0.4 mm and 0.7 mm), we will need to develop a new thermoplastic material, a new design of tools for injection molding together woth an appropriate hard surface coating, enables appropriate hardness, self lubrication and non-stick effect. This will enable that the polymer material can flow through the tool in an optimal way without sticking to the tool surface with minimal friction between the tool and the polymer material. Therefore, the appropriate coating material and coating technology to pile up the coating material to the moulding tool will be one of the decisive parameters to reach the demanding and equably distributed thickness of the polymer coating on the rotor. We will also have to develop the entire production process including the automation conditions. A stator pack with thin insulation layer (0,4 – 0,7 mm) will gain us a decisive advantage over our competitors, since we will be the first to develop such a stator pack for it's use in EMs for the car industry.
Acronym: 
NT_POLYCOAT
Project ID: 
6 778
Start date: 
01-11-2012
Project Duration: 
36months
Project costs: 
650 000.00€
Technological Area: 
Machine Tools technology
Market Area: 
Motor Vehicles, Transportation Equipment and Parts

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