“Hybrid Drivetrain” for Motorsport and Transportation applications

A Global manufacturer of “Hybrid Drivetrain” for Motorsport and Transportation applications. A key market for flywheel energy storage technology is the public transport sector. This technology can save fuel and reduce green house gas emissions by up to 30% in a city bus for example.

Challenges

• Design/Manufacture Tooling for Laminations from 0.1mm electrical steel.
• Demanding tolerances – sub 30 microns
• Prototyping solutions needed to be fit for producing volume.
• Burr free requirement in stamping process

Solutions

• Develop supply chain for raw material.
• Agree geometry of lamination profile.
• Produce prototype samples from Wire Erosion.
• Design and build complex compound tooling for volume production
• “Develop catcher unit” to remove part from tooling
• Contact CMM program for in process inspection.

Brief description of what difference we made… immediately and longer term:

1. Delivered high quality Lamination to specification
2. Developed cost effective process for volume production.
3. Created a material supply chain that did not exist.
4. Provided the customer with the first Laminations of its type.

Added Value

1. Established a clear competitive advantage for the customer in this field of technology.
2. Optimised future product scope, provided the platform for next generation product, establishing a successful route of manufacture.
3. Enhanced the customers Supply Chain by introducing other organisations that could add value to the project.