Rotor shafts

for electric vehicles

What is a rotor shaft?

Rotor shafts are core components of electric motors for electric vehicles. They transfer the mechanical energy generated by the electromagnetic interaction between the rotor and stator to the drive shaft, which enables the vehicle to move

Main functions of a rotor shaft:

  • Transmission of rotary motion: Rotor shafts are largely responsible for the conversion of electrical energy into mechanical movement of the drive train.
  • Stability and precision: The rotor shaft must be able to withstand high speeds and forces, while being manufactured with extreme precision to ensure the smooth operation of the electric motor.
  • Weight reduction and energy efficiency: Modern rotor shafts are designed to be lightweight but yet strong, which contributes to the efficiency of the overall vehicle and optimizes the range of electric vehicles.

Challenges in the manufacture of rotor shafts:

The production of such components requires a combination of the highest precision, material strength (one-piece solutions) and flexibility or combination possibilities in the manufacturing processes (GFU process “high-speed end-forming” + GFU process “Upsetting”) to meet the growing demands of the electric vehicle market.

Solutions from GFU - Maschinenbau GmbH for the production of rotor shafts

Chipless forming of rotor shafts with GFU - Maschinenbau GmbH

Arrange a consultation

Quelle: https://link.springer.com/chapter/10.1007/978-3-662-66894-8_5

1. our expertise in chipless forming technology:

GFU – Maschinenbau GmbH is a leading supplier of state-of-the-art, chipless forming machines. These machines make it possible to produce rotor shafts for electric vehicles with high precision, repeatability and efficiency. Our forming solutions offer the following advantages:

  • Higher material utilization: Compared to machining processes or welding process, chipless forming clearly minimizes the use of materials.
  • Higher strengths: One-piece solutions achieve significantly higher strengths for the rotor shafts. These, in turn, allow a weight-optimized design of the powertrain and therewith longer mileages per kW of the electric vehicles.
  • Environmentally friendly production process: Less waste products and an energy-efficient manufacturing process support sustainable production goals.

2. production methods of GFU - Maschinenbau GmbH:

2.1 Upsetting machine (TFM 150 e-line):

Upsetting is a highly efficient forming process for partial axial upsetting of material in component-critical areas (e.g. gearing areas, etc.)

This process is perfect for the production of rotor shafts because it achieves high precision in shaping and the possibility of massive compression of material in sub-areas.

The TFM 150 e-line is one of our most advanced, electrically driven upsetting machines, characterized by energy efficiency, repeat accuracy and easy integration into existing production lines. This system enables the production of particularly robust rotor shafts with the lowest possible weight and with the desired material upsetting in critical areas of the rotor shaft.

TFM 150 e-line Stauchanlage für die Umformung von Rotorwellen

2.2 High-speed end-forming (e.g. with the RM 100 + TFM 100 e-line):

Flow-rolling is a process for the precise and fast forming of stepped rotor shafts (diameter jumps, step jumps), in which the workpiece and the forming calotte also rotate. The process even enables a material flow of 90° in the transition area with simultaneous significant material thickening in the transition area.

Fließrollierte und mechanisch bearbeitete Rotorwelle im Querschnitt, mit Größenvergleich durch Kugelschreiber.

Combined with the homogenous fiber flow this significantly improves the mechanical properties of the shafts compared to other manufacturing processes available on the market.

Our RM 100 + TFM 100 e-line flow-rolling machines offer the perfect combination of precision, forming speed, energy efficiency and component design for rotor shaft production. These machines enable to shape particularly complex geometries, which has a positive effect on the efficiency of the electric motors.

3D-Modell einer automatisierten Produktionsanlage für Rotorwellen mit Schutzvorrichtungen.

3. machines and equipment for rotor shaft production:

Our machines are tailored to the specific requirements of rotor shaft production and can be supplemented by customer-specific adaptations. Here are some key features:

  • Automated processes: Our systems, such as the TFM 150 e-line and RM 100 + TFM 100 e-line, are fully automated and can be integrated into existing production lines uncomplicated.
  • Flexible production: Thanks to modular tool concepts, you can produce rotor shafts of different sizes and shapes using the same machine.
  • Reliability and precision: Our machines are designed for high durability and precision, which is crucial for mass production.

Conclusion:
With GFU – Maschinenbau GmbH, you not only get high-quality machines for rotor shaft production, but also tailor-made solutions that promote efficiency, sustainability and precision in electromobility.

Get in touch