| Time: | March 14, 2024 |
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This workshop on March 14, 2024, will address the joining challenges in e-axles and e-engines:
In most electric vehicles, the e-machine, a single-stage transmission, the differential, and even the power electronics are integrated to form a so-called e-axle. This is aligned between the front or rear wheels and the drive power is transmitted to the wheels via cardan shafts. This means that the electric axle is exposed to corrosive influences and, in particular, the shaft and rotor of the installed electric motor are subject to high load changes. The housings of the electric axles are usually made of die-cast aluminum. Because of the geometric complexity of the housings, monolithic designs are often not economically viable for large-scale production. Hence, cast parts and other semi-finished forms must be joined together, both detachably and non-detachably.
The stator of the electric motor currently mainly uses hairpin windings, which contain around 400 joints. If just one of these joints fails, the vehicle loses a third of its drive power; if a second joint fails, the electric motor fails completely. This leads to complex requirements regarding robustness, reproducibility, mechanical integrity, and particularly vibration resistance of the joints. The workshop will therefore look at the different joining points, the processes used and the complex requirements in the electric motor with the subcomponents housing, electric motor, rotor, output shaft and power electronics.
- Design and construction methods of electric axles
- Production of cooling jackets and challenges in joining cast housings
- Joining requirements in the production of motor windings
- Joining in rotor, stator and shafts
