Magnetics Business & Technology - March/April 2022 - 21

PRODUCT NEWS
bdtronic Tech Center Helps Define Production Process for EV Manufacturer
an area of more than 650 square meters which are equipped
with series production equipment. More than 20 specialists from
various professional disciplines ranging from chemists with
doctorates and engineers to plant mechatronics engineers work
at the center. Based on the selected material, component and
production requirements, they define the process parameters
for series production alongside customers.
For more information see www.bdtronic.com
Manufacturing the stators for today's advanced
electric vehicle motors can require some tricky
steps involving complex technology solutions. One
specialist in providing such solutions is bdtronic of
Germany which recently used its expanded technology
center to work with an EV manufacturer
to establish an effective process and machinery
approach. The effort at the center helped the company,
a process specialist for trickle varnishing of
electric motors, recently receive a large order for
its powder coating equipment from the unnamed
German OEM.
A key challenge in manufacturing modern hairpin
stators is that the welded zones of the stator
need protection from external conditions in order
to achieve electrical insulation. bdtronic offers
a modern manufacturing process to cover the
coating of the stators' welded pins with epoxy
powder to ensure a safe and reliable product. The
technology complements the impregnation of H/
EV motors in the powder coating process. This
means that impregnation and powder coating can
be offered from a single source to ensure process
reliability and quality.
The process for hairpin winding calls for rectangular
bars of magnet wire to be bent into a hairpin
shape. They are then inserted into the slots of the
stator in the axial direction. The ends of the hairpin
coils are then welded so that the connected coils
form a wave shape.
bdtronic has developed a special heating solution
that avoids large meter-long ovens to ensure
efficient, energy and space saving production. To
insulate the welding tips on the stator, the part is
preheated and moved into a powder bath. Thanks
to the heat of the stator, the epoxy melts on the
surfaces and forms a protective layer. With this
process, the customers get a uniform covering
of the pins and an efficient solution for surface
imperfections.
Leading up to the recent order, bdtronic helped
convince the OEM by conducting successful trials
in its recently enlarged technology center in
Weikersheim. The center has 11 rooms covering
www.MagneticsMag.com
Optimize the electrifi cation properties
of your EV power electronics
& electric propulsion systems
Achieve near-perfect magnetic circuits
with our tape wound toroidal & cut
cores, specifi cally designed to:
* Outperform transformer laminations,
* Minimize electrical losses,
* Reduce component size & weight,
* Increase power density,
* Maximize performance characteristics
Our cores deliver the essential
magnetic properties and effi ciencies
required for:
* Transformers that power EV Charging
Stations,
* Transformers that control &
monitor AC induction & DC motor
performance,
* Power supplies that charge EV
battery packs,
* GFCI's used in
Electric Vehicles,
* Inductors,
converters &
inverters
We utilize the
most advanced
grades of
soft magnetic
materials, provide
short turnaround
times, and offer
both standard
and custom cores.
Contact us today to discuss which
magnetic materials and core designs
will give you EV components with
maximum electrifi cation properties.
75+ YEARS
OF CUSTOMER
SERVICE
Phone: (856) 964-7842
Fax: (856) 365-8723
www.magneticmetals.com
© 2021 Magnetic Metals Corporation
March/April 2022 * Magnetics Business & Technology 21
http://www.bdtronic.com http://www.magneticmetals.com http://www.MagneticsMag.com
Magnetics Business & Technology - March/April 2022

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