For more than 20 years, Windings has helped pioneer the development of brushless DC electric motor
solutions that support the electrification of motor vehicles. From hybrid / electric passenger
cars and commercial vehicles to Formula 1 racing, Windings has partnered with Automotive
industry leaders to design, test and manufacture custom electric motors, generators and related
components including rotors, stators, lamination stacks and insulation systems. By partnering closely with clients from initial concept through product design and part production, Windings’ Design Engineers and Product Managers act as an extension of our client’s project team to optimize part performance, reliability and manufacturability while minimizing time to market.

As a full-service provider, Windings is a leader in the innovation, optimization, prototyping, testing and manufacturing of custom electric motors, generators and related components including rotors, stators, lamination stacks and insulation systems intended for mission critical automotive applications. One of the things that makes Windings unique is our stance on ownership of intellectual property. Unlike most motor manufacturers, Windings allows our client to retain ownership of any unique intellectual property developed during the project, offering maximum flexibility for clients over the life of the product.

From the early development of transmission components for commercial hybrid electric vehicles to the latest state-of-the-art electric turbochargers and propulsion motors used in Formula 1 and Formula E racing, Windings’ engineering talent and manufacturing expertise puts you in the driver’s seat.

Frequently Asked Questions

What is IP69K environmental protection?
IP69K is a product standard which describes the abilty for a device to withstand certain enviornmental conditions.
What kinds of motors are used in electric vehicles?
Electric vehicles use permanent magnet and induction motors.
What are the advantages / disadvantages of hairpin stators?
Hairpin stators have benefits for producing in high volume at low cost but the disadvantage of initial higher tooling costs.
How to retain magnets in high speed electric motor operation?
Magnets are retained by covering them under pre-stress by the use of metal sleeves or fiber retention systems.
How are magnets retained on a rotor?
Magnets are retained by gluing or bonding them to the rotor shaft and in cases of high speed, a supplemental sleeve is used. In cases of IPM structures, the magnets are retained by the steel of the rotor laminates.

Automotive Motor Solutions From Windings Offer:

  • IP69K environmental protection
  • Proprietary insulation system, allowing operation up to 260 degrees C
  • High reliability (15 year design life)
  • Highest efficiency (over 96%) permanent magnet construction
  • Protection against aggressive media/fluids (ATF)
  • High shock and vibration tolerance

Motor Technologies

  • Brushless DC Motors
    • Surface Mount Permanent Magnet
    • Interior Permanent Magnet (IPM)
  • Three- and Five-Phase Induction Motors

Development Focus

  • Motorsports
    • Electric turbochargers for Energy Recovery Systems (ERS)
    • Motor Generator Units (MGUs) for Kinetic Energy Recovery Systems (KERS)
  • Passenger Cars
    • Primary propulsion for electric vehicles
    • Electric transmissions for hybrid vehicles
    • Electric compressors
  • Commercial Vehicles
    • Electric transmissions for mass transit vehicles
    • Electric fuel pumps for diesel engines

Certifications

Windings leverages its Quality Management System (QMS), and strong heritage and experience in the Aerospace and Automotive industries, to comply with standard Automotive Quality Compliance Measures (APQP, PPAP, etc.)

  • Dual certifications to the ISO 9001:2015 and AS9100 (Rev D) quality management systems
  • Compliant with EU Directive 2002/95/EC, Restriction on Hazardous Substances