Individual sheet manufacturing

Our extensive machine park has capacities for individual part production and serial part production for a diverse range of applications. We are able to select the optimal method of cutting for the given project, whether it is stamping, laser cutting, or using water jets. A deburring and coating plant deburrs and repaints the metal sheets, so that these sheets can be used in electrical machines without the formation of eddy currents.

Procedures

Laser cutting

The programmable machine control of the laser cutting units allows the production of any desired contour for the electric machine.

With a very low cutting tolerance and a high repeat accuracy, this procedure is the optimum solution for the production of high-quality contours.

It is used for the manufacturing of prototypes, repair and small series of electric machines, but also for realising deliveries of electrical sheet contours within a short time frame.

Technical parameters

Material thicknesses:

  • Thin sheet metal and electrical sheet from 0.2 mm to 3 mm
  • Steel panels (mild steel) from 3 mm to 20 mm
  • Max. working area: 2,050 mm x 4,000 mm

For thin sheet metal and electrical sheets up to a thickness of 1 mm we guarantee a cutting accuracy of +/- 0.05 mm.

 

Water jet cutting

For contours that cannot be cut using the laser cutting method, we apply our water-jet cutting system.

With a pressure of up to approx. 4,000 bar and the addition of an abrasive agent, non-ferrous metals up to 100 mm, aluminum up to 250 mm and steel up to 100 mm material thickness can be processed.

As this procedure allows the processing of a large variety of materials, many parts of the electric machine, such as pressure plates, press rings or copper parts can be manufactured.

Technical parameters

Water-jet cutting with and without abrasive agent at pressures of up to 4,000 bar for a variety of 2D contours.

Typical materials:

  • Stainless steel up to 100 mm
  • Mild steel up to 100 mm
  • Aluminum up to 250 mm
  • Non-ferrous metals up to 100 mm

Max. working area:

  • 3,000 mm x 3,000 mm

Additional materials and material thicknesses may be feasible following technical evaluation.

Post-treatment of sheets

During the manufacture of electrical sheet contours, a cutting burr is created, which can cause an electrically conductive contact between the sheets when pressing the laminated core. This facilitates the generation of eddy currents over various sheets, thus increasing the hysteresis losses of the laminated core.

This effect can be eliminated by post-treatment of the electrical sheets.

During post-treatment the cutting burr is removed and the sheet is recoated on both sides.

Deburring and coating of electrical sheets

  • Removal of cutting burr on cut and punched contours
  • Subsequent application of insulating varnish on both sides of the sheets
  • Workpiece length: 350 mm to 1,250 mm
  • Workpiece width: 350 mm to 1,250 mm
  • Workpiece thickness: 0.35 mm to 1.0 mm

Coating specifications

  • Viscosity: 60 to 150 DIN 4s
  • Minimum application thickness: 2 to 3 μm on each side, dry

Technical parameters

Processing sheets from the coil

  • Max. coil weight: 10 t
  • Max. Coil width: 1260 mm
  • Max. sheet thickness: 1.0 mm
  • Min. sheet thickness: 0.35 mm

Spot welding of sheets

  • Spot or projection welding of sheets for the production
    of ventilation and cover plates.

Assurance for individual sheet production

After production of the first sheet, it is inspected directly on a light measuring table. Here a qualitative evaluation is performed of the dimensional accuracy. If necessary, a correction of the cutting parameters is made to fulfil the tolerance requirements. In general, the contours of the sheet are evaluated on our light measuring table before further production is approved.

Reverse Engineering

For the repair of machines, it is typically sufficient to receive one individual sheet. The contour is scanned and digitalised. After reconstruction on a CAD computer, the data is transmitted to the laser cutting system. The reconstructed sheet can be cut.

For new production, it is suffi cient if we receive per PDF file the corresponding dimensions. The use of DXF or DWG fi les presents no problems. It should be mentioned here that we always have a sheet coil stock with approximately 500 t – 600 t in various electrical sheet quality.

Merken