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Inno­v­a­tive motor lami­na­tions in the ECI module

How tech­nical improve­ments lead to cost reduc­tions

Opti­mi­sa­tion of the magnetic circuit

Attrac­tive prices and indi­vid­u­ally customised design are the objec­tives of our devel­op­ment depart­ment. The prereq­ui­sites for this are flex­i­bility and ever more advanced stan­dards in the inside of our drives. This is under­scored by the new motor lami­na­tions for our ECI module. In this article, I want to talk about some of the tech­nical and cost-cutting high­lights.

All common motor diam­e­ters, ECI 32, 42, 52, 63 and 80, are included in the new stan­dard. In multiple iter­a­tion loops, we have opti­mised the magnetic circuit and the contour of the sheet steel so that a reduc­tion of the detent torque by approx­i­mately 10 percent could be achieved. Simul­ta­ne­ously, this increased the power density by approx­i­mately 70 percent. With the ECI 6360, which has a motor size of 63 and an active motor length of 60 millime­tres, a torque of 1 Newton-meter and an output of 420 watts is now attained. Basi­cally, the length is flex­ible up to the maximum design; the preferred lengths are defined at 20, 40 and 60 millime­tres. The end shields required for insu­la­tion can be used with the groove paper insu­la­tion for all lengths. The winding connec­tions are defined with high preci­sion, enabling a high degree of automa­tion. To this is added the newly devel­oped connec­tion ring, which has a stan­dard­ized config­u­ra­tion that permits all conceiv­able connec­tions. In close collab­o­ra­tion between all members of the devel­op­ment team, we have designed the rotor and stator such that they can always be punched at the same time, thus avoiding waste of mate­rials. For cost reasons, the magnets also have a cube-shaped design that is clever enough to allow the same magnets to be used for motor diam­e­ters ECI 32, 42 and 52; only their number differs according to the motor diam­eter. The connec­tions and modules have been qual­i­fied in exten­sive tests and the series intro­duc­tion has already taken place with the ECI 42 and ECI 63.

ECI 63 with K5 elec­tronics

In summary, I can say that the tech­nical improve­ments offer our customers solu­tions previ­ously attain­able only with larger drives and provide a cost benefit that applies even for smaller quan­ti­ties, while also opening up new markets and appli­ca­tions. With the ECI module, we see great bene­fits for indus­trial drive engi­neering, intral­o­gis­tics, medical tech­nology or a wide variety of appli­ca­tions in this market. In addi­tion, the bene­fits are evident in the auto­mo­tive area for driving pumps, steering appli­ca­tions or adjust­ment require­ments that impose strin­gent demands on the tech­nical config­u­ra­tion while simul­ta­ne­ously meeting the price targets.

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