Innovative manufacturing solutions for 48V Mild-Hybrid-Systems
With the help of 48V technology, the well-known "alternator" becomes a powerful starter generator that supports the combustion engine as an auxiliary unit. This type of hybridization has become known as mild hybridization.
Belt starter generators (BSG) and gear-integrated starter generators (ISG) have established themselves as types. In the meantime, both are preferably realized in plug-in coil technology, so-called hairpins.
Aumann has know-how in the entire process chain for stators, rotors and ready-to-install complete systems of this type of hybridization.
We combine the wide range of forming, winding, contacting and assembly processes with a needs-based degree of automation to create the optimum manufacturing solution.
Processes/expertise 
- Shaping profile wire into plug-in coils (hairpins)
- Laser removal of the lacquer insulation from the weld spots
- Lining/insulating the stator slots
- Hairpin assembly
- Cropping, twisting and final trimming of the wire ends
- Laser welding of the wire ends
- Various winding and assembly techniques for rotor production
- Complete assembly and EoL testing.
