Stator Housings

NETFORM offers three different processes for producing stator housings for EV motors.

These include:
  • Flowformed stator housings
  • Press-formed stator housings
  • Rolled & welded fabricated housings

Each of the processes has potential benefits, the extent of which will depend on the application being considered.

Flowformed Stator Housings
  • One-piece construction
  • Work-hardened wall
Press-formed Stator Housings
  • Suitable for housings less than 100m in length
  • Cost-effective process
  • One-piece construction
Rolled & Welded Fabrications
  • Suitable for modular applications – common flange, multiple lengths
  • Flexible production process

Product Domain

EV

Hybrid

Cold Formed Stator Housings

Using a unique NETFORM-developed process that combines cold forming and a stamped drawing process, NETFORM can produce stator housings in a single press hit/single station. Starting with a flat ring, the inner material is stretched down to form the main stator body.

The fact that the housings are formed in a single tooling station leads to lower tooling costs, when compared to progressive or transfer stamping processes. This single-hit process also provides lower cost engineering changes should they be required.

Manufacturing Process

  • The process starts with a flat, stamped blank.
  • This blank is loaded into a cold forming press, the stator walls formed.
  • The formed part is then finished machined as required.

Stamped Blank

Cold Formed

Machined

Cold Formed Stator Housings

Technical Information

  • Materials: Low Carbon Steels
  • Diameter: Up to 500mm Max
  • Max Length: Up to 80mm
  • Work Hardening: Up to 2-3x original strength.
  • Forming capabilities:
    • Potential to pre-machine while in flat state
    • Formed Diameters held as tight as 0.10 mm
    • Faster part to part production and lower tooling cost

Flowformed Stator Housings

The flowforming process provides increased flexibility for the product engineer. The variety of starting preforms available – flat blanks, stampings, forgings – allows a wide variety of finished components to be designed and manufactured.

The process also allows for variable wall thicknesses on the housing, as well as providing a one-piece finished housing.

Manufacturing Process

  • The process starts with a blank that could be a forging or a stamping.
  • The preform goes through the flowforming process and is finally machined as required.

Stamped Blank Preform

Flowformed

Flowformed Stator Housings

Technical Information

  • Materials: Low to medium carbon Steels
  • Diameter: Up to 300mm
  • Max Length: Up to 350mm
  • Work Hardening: Up to 2-3x original strength.
  • Forming capabilities:
    • Variable cross-section possible
    • Excellent material utilization
    • Formed diameters held to ±25mm

Rolled and Welded Stator Housings

This process utilizes advanced CNC equipment to offer a fabricated, laser-welded stator housing. This process has excellent material utilization and is well suited where there is a family of similar parts that need to be manufactured on the same program.

A cut-to-length flat blank is fed into a programmable CNC roller to form the basic tube. This formed component is then precision clamped and then laser welded. The mating flange – which can be laser cut, stamped or fine blanked – is then laser-welded to the tube to form the complete housing.

Manufacturing Process

  • The process starts with a rectangular steel blank.
  • The blank is rolled and laser welded.
  • The tube is then end trimmed.

Flat Blank

Rolled

Laser-welded with flange

Rolled and Welded Stator Housing Design Options

Dual Wall

This process allows for the manufacture of dual walled housings. Dual walls can be used to increase cooling performance of the housing.

Rolled and Welded Stator Housings

Technical Information

  • Materials: Low to medium carbon steels, stainless steel
  • Diameter: Up to 400mm
  • Max Length: Up to 350mm
  • Forming capabilities:
    • Dual wall capability for optimal cooling
      • Cooling inserts customizable for all diameters/sizes
      • Excellent material utilization

Applications

EV Motor

The mechanical power source of an electric vehicle. 

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