Custom drives for compact installations
Limited installation space and high performance requirements as key drivers
In many applications, the demand for high-performance electric motors is growing, even though available installation space—particularly in the axial direction—is limited. At the same time, as the core component of mechatronic systems, drives must meet high standards for dynamics, efficiency, and integration.
In the industry, this challenge has traditionally been addressed using radial-flux-based motor concepts based on stacked laminated core geometries. Customization for small to medium production runs is often only possible to a limited extent, typically through variations in overall length and adjustments to the winding design. Added to this are sometimes high tooling costs, such as for stamping dies, which make it difficult to achieve cost-effectiveness with custom geometries.
The Electric Motor Industry in Transition
The electric motor industry combines a long tradition of engineering with intense pressure to innovate driven by electrification and automation. The market landscape ranges from specialized manufacturers of custom motors to volume-driven corporations producing very high quantities. At the same time, developers benefit from a mature supply industry and a high degree of standardization in peripheral components such as sensors, connectors, and cooling systems, which accelerates integration into complete systems.
Axial-flow motors as an alternative for compact system designs
Axial-flow motors from WEBER-HYDRAULIK are characterized by a particularly compact, disc-shaped geometry. Compared to conventional radial-flow motors, this allows them to be integrated in a space-saving manner when the axial installation length is critical. For designers, this provides additional flexibility in system integration, for example when the motor, mechanical components, and electronics need to be brought closer together.
Overview of the advantages of WEBER-HYDRAULIK axial-flow motors:
- Space-saving integration thanks to a very compact design for tight installation spaces
- High torque density due to optimized magnetic flux guidance
- Flexible installation options in various drive systems
- Technologically mature alternative to conventional radial-flow motors
- Cost-effectiveness for custom designs: reduced tooling costs make customized solutions feasible even for smaller production runs
Integration Concept: Motor, Electronics, and Pump in a Single Assembly
Using electric hydraulic and pump units as an example, WEBER-HYDRAULIK is pursuing an approach that reduces the traditional separation of components. The goal is a highly integrated solution in which the motor, power electronics, and pump unit can be combined into a single assembly. This reduces volume and weight while minimizing cabling and interface requirements.
Another distinctive feature is a brushless rotor, which reduces inertia. This supports high operational dynamics during speed changes, such as in pump applications or dynamic control loops.
Plug-and-play installation and pre-assembled, tested modules
To simplify integration into the customer’s application, a plug-and-play installation concept is provided: The unit is supplied as a pre-assembled, tested module (“pre-assembly”). This approach aims to simplify final assembly in the customer’s production facility, lower process costs, and reduce potential sources of error by minimizing the number of individual components. End-of-line testing supports standardized quality assurance prior to integration.
Further information on the technical characteristics, advantages, and applications of axial-flow motors can be found at axial-flux-motor.weber-hydraulik.com
“Axial-flow motors enable compact drive solutions when installation space and system integration are critical. Thanks to their custom design and integration concept, development and assembly costs in electrohydraulic applications can be specifically reduced,” says Dietmar Andessner, Head of Axial-Flow Motor Development at WEBER-HYDRAULIK.
