LPBF-based, additively manufactured contact ring segments for closed-form coil stators

Vogel A, Wirthmann F, Kilic M, Ihne T, Franke J, Risch F (2026)

Publication Language: English

Publication Type: Conference contribution, Conference Contribution

Publication year: 2026

Publisher: SINTEF Acadmeic Press

Series: SINTEF Proceedings

City/Town: Oslo, Norway

Pages Range: 322-327

Conference Proceedings Title: Proceedings of the 33rd International Conference on Electrical Contacts Trondheim, Norway, 21–25 June, 2026

Event location: Trondheim NO

ISBN: 978-82-536-1888-3

URI: https://nva.sikt.no/registration/019eba644281-5f39e4e7-42de-4445-b47e-97cdab4abf71

Open Access Link: https://nva.sikt.no/registration/019eba644281-5f39e4e7-42de-4445-b47e-97cdab4abf71

Abstract

The stator is the most expensive motor component and thus a prime target for automation, yet steps like insulation assembly and contacting remain largely manual due to the challenge of flexible, and mostly limp wire ends, which can be handled with great effort or by expensive machines or robots at high volumes. In compact, highly power-dense drives that do not use hairpin technology, the coil contacting process must be redesigned to overcome manual operations. A promising approach is to replace manual handling with a contact ring combined with laser-assisted contacting to reduce complexity. The goal is a low-resistance, electrically conductive joint with high mechanical stability. Building on an existing concept, this work introduces an additively manufactured contact ring and precise laser welding.

Authors with CRIS profile

Alexander Vogel Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS) Felix Wirthmann Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS) Thorsten Ihne Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS) Jörg Franke Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS) Florian Risch Professur für Montagetechnologien elektrischer Energiespeicher

How to cite

APA:

Vogel, A., Wirthmann, F., Kilic, M., Ihne, T., Franke, J., & Risch, F. (2026). LPBF-based, additively manufactured contact ring segments for closed-form coil stators. In Magne Runde; Kaveh Niayesh, Åsa Kassman Rudolphi (Eds.), Proceedings of the 33rd International Conference on Electrical Contacts Trondheim, Norway, 21–25 June, 2026 (pp. 322-327). Trondheim, NO: Oslo, Norway: SINTEF Acadmeic Press.

MLA:

Vogel, Alexander, et al. "LPBF-based, additively manufactured contact ring segments for closed-form coil stators." Proceedings of the 33rd International Conference on Electrical Contacts Trondheim, Trondheim Ed. Magne Runde; Kaveh Niayesh, Åsa Kassman Rudolphi, Oslo, Norway: SINTEF Acadmeic Press, 2026. 322-327.

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