Precision Cutting of Stator Plates for e-mobility Applications

E-mobility will continue to rise in terms of adoption, causing a number of challenges to electric vehicle manufacturers in many areas of operation. There is not only the scale of production required, but there are also the precision manufacturing demands created by electric vehicles. In this article, we discuss how fiber lasers can help with the precision cutting of stator plates, just one of the many high-precision requirements created by e-mobility.

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Stator from an electric motor

What is the stator in an electric motor?

The stator is the part of an electric motor, which remains stationary. The stator consists of a steel frame, which encloses a hollow cylindrical core. The primary purpose of a stator is to ensure the electric field is aligned correctly.

Upon applying an electrical current the electromagnetic stator is energised by the coil with the flow of electricity. The coil is most frequently made of aluminium (sometimes iron), to minimise power loss a conducting material such as copper is wound around the coil.

The challenge of precision stator plate cutting

Electric vehicle manufacturers face numerous challenges with regard to precision stator plate cutting:

  • Precision – The level of precision required to accurately (faultlessly cut stator plates)
  • Scale – The scale of production anticipated due to the large-scale ramp-up of e-mobility
  • Speed – Stator plates need to be produced with great speed to keep up with demand

Fiber lasers such as those from SPI Lasers, meet the requirements of working precisely, at scale and to high speed levels.

The stator plate cutting process

Electric vehicle Manufacturers are turning to fiber lasers for the cutting of stator plates. The process starts with sheets of specially manufactured steel for electric vehicles. A cutting process is programmed into the laser and then the sheet is cut to the precise specifications of the stator without faults. Advantages of the process include:

  • Error free – the process is error-free when compared to traditional cutting methods, which is critical for electric vehicle reliability. Any human errors are removed in this process
  • Minimal waste – the laser is programmed to minimize sheet steel waste, any sheet left over can easily be recycled as a part of environmentally-friendly initiatives
  • Non-contact – the process is totally contact-free, the steel is cut remotely through the laser beam, reducing employee injury risk and contamination
  • Precision – the precision level is absolute; the stator is cut exactly to the specification required
  • Prototyping and small-scale production – the process can even be used in prototyping and small-scale production models without the need for special tooling
  • Repeatable – the cutting process is highly repeatable and is perfect for large-scale manufacturing processes

A video providing a demonstration of a fiber laser in the process of cutting

SPI Lasers – precision laser cutting for e-mobility

Although laser cutting is just one of the applications, which a laser from SPI Lasers can perform we appreciate it’s an important one! SPI Lasers are committed to e-mobility, which we know has a bright future and we would love for you to join us on the “journey”. Why not contact SPI Lasers to discuss how we can help your organisation address its precision cutting needs as well as the  wider demands of e-mobility. If you have enjoyed reading this application insight, click this link to receive future updates automatically.



Image Credit: Wikipedia


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