The Mobility of Tomorrow
New Mobility
Mit über 60 Jahren Erfahrung in der Werkstofftechnik von Kunststoff, Kupfer und Eisen ebnet schlaeger den Weg in die elektrische Zukunft der Mobilität. Aufbauend auf unserer Tradition entwickeln wir schon heute Lösungen für die Mobilität von morgen – elektrisch, nachhaltig und effizient.
Our focus is on the development and production of assemblies and components for electric drives, characterized by exceptional robustness and high functional integration. These include, among others, thermal management systems for electric vehicles, stator segments for the transmission-integrated e-machine, innovative drive solutions such as bicycle motors, as well as complex mechatronic assemblies.
With our new electric motor microfactory, we can respond flexibly and efficiently to the individual needs of our customers – from prototypes to series production in the millions. Thanks to our expertise in plastics engineering, mechatronics and process integration, we deliver solutions that not only enable efficient magnetic field generation, but also meet the requirements of future mobility.
What schlaeger Delivers
in the New Mobility Sector
Our goal is to actively shape the future of mobility with advanced mechatronic solutions in electromobility and the development of efficient stators and rotors – ecologically responsible and technologically leading. Our development ranges from highly integrated metal-plastic components to pre-assembled stators, always focusing on the specific requirements of our customers. Key highlights include:
- Pump stator housingswith interconnected pole chains above d = 9 mm
- Robust and efficient stator segments for transmission-integrated electric machines
- Efficient magnetic field generation and high functional integration in single poles and stators
Our highly integrated single poles are created either with multi-part assembled insulation or via thin-wall overmolding. Orthocyclic winding layouts as well as direct winding of flat or edgewise rectangular wires maximize the copper fill factor, reduce phase resistance and increase power density. Precision laser stripping technology – optionally with tin plating – creates perfect contact surfaces for your interconnection, while reserved installation spaces integrate thermal sensors directly into the segment. Result: single poles in true high-volume production quality, ready for automated stator assembly.
Radial or axial flux machine
Multi-part assembled insulation or thin-wall overmolding technology
Orthocyclic winding layout
Direct rectangular wire winding (flat / edgewise)
Laser stripping with/without tin plating
Integrated thermal sensor installation spaces
MHEV & PHEV up to 400 V
This is where we achieve the highest power densities – while also understanding challenges such as heat dissipation and maximum temperatures. The expertise lies in the combination of product design and winding technology: whether as chain winding, phase conductor without many contact points, or as an interconnected single pole using resistance and/or laser welding technology – the solution is always found in product knowledge combined with process expertise.
Our axial flux architecture in the diameter range from 40 to 100 mm combines several functions in a single injection molding process: molded insulation integrates interconnection contacts, customer-specific terminals, connectors as well as structural mounting points. Winding is carried out on modern needle winding machines – fast, wire-friendly and highly precise – ensuring excellent insulation quality and minimal phase resistance.
Thanks to outstanding diameter tolerances, many downstream assembly steps are possible, including shrink-fit processes, can-type assemblies or our media-tight stator overmolding, which creates separated chambers in a single forming process without affecting dimensional accuracy. Overmolded claw-pole stators for actuators can also be realized – a highly integrated solution from a single source.
Applications
Stators for media pumps & blowers
CAD study of claw-pole stators
Our complete-cut architecture covers the diameter range from 40 to 100 mm and is optimized for automated high-volume production. In injection molding, insulation parts are created that combine interconnection contacts, customer-specific terminals, connectors and structural mounting points in a single forming process – highly integrated and cycle-time stable.
Winding is performed on modern needle winding machines: fast, wire-friendly and highly precise. The result is high insulation quality and low phase resistance, increasing efficiency and service life.
Our excellent diameter tolerances enable a wide range of downstream assembly options such as thermal shrink fitting, can-type assemblies or our media-tight stator overmolding, which creates separated fluid chambers without compromising dimensional accuracy. We also supply overmolded claw-pole stators as compact, highly integrated solutions for actuators.
Stators for media pumps & blowers
CAD study of claw-pole stators
Our patented injection molding assembly permanently anchors up to 30 magnets in a single shot within the lamination stack of the rotor disk, creating a cost-efficient, high-strength basis for traction machines. Building on this, we develop assembly injection molding processes for smaller rotors that integrate magnets, flux return, bearings or shafts in a single process step. Subsequent magnetization, dynamic balancing and – if required – completion into hydraulic impellers using material-bonding welding technologies result in highly integrated and robust assemblies.
Our multi-stage injection molding processes run on 2K machines with rotary platen technology or inline-combined units and are media-tight against oil, coolant and ATF – reliable even under the most demanding operating conditions.
Applications
- Rotors for pumps
- Rotor disks for electric drives
Our rotor assemblies for externally excited synchronous machines (FSM) combine thin-wall, high-voltage-resistant insulation with precise interconnection and contacting technology. Robust encapsulations permanently protect windings and solder joints, while optional interfaces for structural add-on components absorb high centrifugal forces at high rotational speeds.
Depending on system requirements, we integrate slip ring carriers for conventional power supply or inductive transmission systems for wear-free excitation. Wound pole teeth – for example in a 9-pole topology – are supplied ready for installation either as an individual component or as highly integrated assemblies.
Applications
- Slip ring carriers
- CAD study for wound pole teeth on a 9-pole rotor
We create spaces for arc extinction and integrate magnets, gas-tight chambers, thermally optimized surfaces as well as flame protection according to UL94 V0 in a multi-stage overmolding process. This resource-efficient approach delivers robust, high-precision assemblies for volumes from several thousand to the millions. Based on decades of experience in linear actuators, ready-to-install magnet assemblies are created for disconnect and isolation relays.
Our glueless technology eliminates adhesive and curing processes and enables highly automated series production. Precision tooling sets tolerances exactly where they matter. This allows us to manufacture assemblies made of flame-retardant plastic (UL94 V0), round or rectangular conductors with high current-carrying capacity, as well as litz wire packages with up to 1,000 individual conductors for minimal skin effect. Where required, ferrite cores are overmolded in a single step. This results in customized solutions for DC/DC converters and on-board chargers in the multi-kW range – 100% “made in Germany”.
Our ready-to-install temperature sensors are applied directly to the stator copper conductor, then high-voltage tested and delivered as a complete assembly. The result: fast, precise temperature data for active overtemperature monitoring and adaptive control strategies in the electric drive.
Features
Direct conductor temperature measurement (stator copper)
High-voltage-resistant series testing
Plug-and-play installation
Fast response time
Valid data for motor protection & thermal management
