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The increasing electrification of drive systems is leading to a growing variety of hairpin stator designs, while development cycles continue to shrink. Traditional prototyping processes—relying on series-oriented special tooling and sequential development workflows—are increasingly reaching economic and time-related limits. Long procurement lead times, high one-off tooling costs, and limited integration between development and production complicate the efficient realization of early prototype stages. Against this backdrop, Gehring Technologies GmbH + Co. KG has developed an integrated digital process chain that systematically links geometric development, simulation-based process validation, and series-oriented prototype manufacturing. The objective of this approach is to validate development decisions at an early stage, significantly reduce iteration loops, and ensure industrial feasibility already during the prototyping phase. The foundation is a modular software toolkit consisting of parametric geometry modeling (Winding Designer), process-specific forming simulation (Twist Simulator), and automated geometric quality analysis (PinStudio). These modules can be used independently or combined into a continuous digital development and manufacturing chain—suitable for both prototyping and series production. Parametric Development as a Driver of Product Creation At the core of the development phase is the Winding Designer, a parametric modeling tool for hairpin stators. Instead of conventional CAD design, the system generates the complete stator geometry directly from electromagnetic target parameters. Spatial constraints, manufacturing conditions, and geometric dependencies are embedded in the model, allowing the design to be algorithmically derived from relevant input parameters. This approach enables development speeds unattainable with conventional CAD processes. Changes to conductor routing, end-winding geometry, or interconnections can be implemented almost in real time. The model updates automatically, including all derived process geometries. Development engineers can therefore generate, compare, and evaluate variants interactively.

As Dr. Ludwig Hausmann, Head of Analytics and Modeling at Gehring Technologies, explains: “Using the Winding Designer, we can perform geometric adjustments in real time. This speed is not achievable with traditional design methods - it fundamentally changes the dynamics of the development phase.” A key advantage lies in shifting the developer’s focus toward functional design. Instead of detailed geometric construction, the emphasis is placed on electromagnetic target definition. The system handles geometric implementation while accounting for manufacturing constraints. At the same time, key metrics such as conductor length, copper mass, and electrical resistance are automatically calculated and made available for further design optimization. Dr. Andreas Wiens, responsible for technological development at Gehring Technologies, emphasizes: “Component geometry is now derived directly from electrical targets. Manufacturing aspects are considered from the outset, significantly reducing later correction loops.”

(https://www.powertransmission.com)

More About FK:

FK Bearing Group Co.,Ltd. was orignally founded in 1969 and always focuses on Bearing Units in the past 50 years. FK has complete industrial chain automatic factory of its own, now FK is one of the biggest bearing parts factories in China with annal production and sales up to 18 million pieces.

www.fk-bearing.com

2026 New Week FK Product Recommendation:

722500 DA/DB:

The 722500 DA/DB is a type of Plummer Block (bearing housing) designed to support rotating shafts with rolling bearings. It features:

Robust cast iron or steel housing, suitable for heavy-duty applications.

DA/DB variations may refer to different sealing or mounting designs (e.g., DA with set screws, DB with double seals).

Easy installation and maintenance, ideal for industries like conveyors, motors, fans, and mining equipment.

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