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Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13. Show image information
Partner of the DMRC Show image information
Partner of the DMRC Show image information
Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC Show image information
Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part Show image information
Additive manufactured reaction wheel bracket for telecomunication satellites Show image information
Employees of the DMRC working with the "freeformer" from Arburg Show image information
Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM) Show image information
Powder particles are used as raw material for laser-based additive manufacturing Show image information

Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13.

Partner of the DMRC

Partner of the DMRC

Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC

Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part

Additive manufactured reaction wheel bracket for telecomunication satellites

Employees of the DMRC working with the "freeformer" from Arburg

Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM)

Powder particles are used as raw material for laser-based additive manufacturing

Lightweight Rotor Shaft for PMSM

Objectives
The aim of the project was the identification of benefits of Additive Manufacturing (AM) in electric engineering and especially the implementation of this benefits in a Permanent Magnet Synchronous Motor (PMSM)

Figure 1: Optimized rotor shaft with lattice structures for a lightweight design

Procedure
An optimal material was determined (H13) and its mechanical and electromagnetic properties were investigated and improved by a heat treatment. A suitable PMSM was selected and its rotor shaft design was optimized for AM. The rotor shaft was built out of H13 and mounted into a given stator. Finally the motor characteristics were determined.

Figure 2: Results of the motor characteristics investigations

Achievements
The promising results of the motor characteristic determinations showed that the weight of the rotor shaft could be reduced by 25,1%. This leads to a reduction of the moment of inertia of 23% and an reduction of the acceleration time of 23,2 %. The Investigations were performed at 71,98 Nm and 3000 rpm. Moreover the permeability of the material H13 could be improved through a heat treatment. So the permeability could be enhanced from 32 to 480 and the coercivity could be reduced from 5600 A/m to 1300 A/m. This lead to an obvious enhanced soft magnetic behavior.

The project was funded by the Forschungsvereinigung Antriebstechnik (FVA, engl.: Research Association Drive Technology).

Specific the work group “Geregelte Elektroantriebe” (GEA, engl.: Controlled Electric drives) with its industrial members like Siemens, Wittenstein, Porsche, VW, Wilo. The scientific partners were the chairs IAL (University of Hanover) and the IAM (Karlsruher Institute of Technology)

Contact

Prof. Dr. Detmar Zimmer

DMRC

Additive Manufacturing: Design Rules, functionality, function integration

Detmar Zimmer
Phone:
+49 5251 60-2256
Fax:
+49 5251 60-3206
Office:
P1.3.17

Stefan Lammers, M.Sc.

DMRC

Design technology (design guidelines)

Stefan Lammers
Phone:
+49 5251 60-5472
Office:
W2.103
Web:

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