Additive-subtractive manufacturing of multi-material sensor-integrated electric machines using the example of the transversal flux machine

Electro mobility is playing an important role when it comes to reducing the CO2 emissions of vehicles. The drive train in particular must be designed efficiently in order to achieve the highest possible degree of efficiency. The transverse flux machine (TFM) has an enormous torque and allows efficient, highly dynamic operation. This enables stepless power transmission over the entire speed range as well as short-term overload. However, in order to produce efficient TFMs with high efficiency, highly flexible production processes are required to create the best possible magnetic properties in the air gap between the rotor and stator of a TFM. In this paper, three processes are presented that are intended to improve the properties of TFMs. Firstly, ceramic insulation layers were analysed and characterised using Direct Energy Deposition (DED). Secondly, complex hard magnets were produced using vat photopolymerisation (VPP). Thirdly, using an additive-subtractive fused filament fabrication (FFF) process, various contact types for sensor circuits were investigated with regard to electrical resistance. With the help of sensor circuits, preventive condition monitoring is to be made possible.