About Us / Production Processes
Totally Vertical Integrated
In our press shop, the raw material of high quality electrical steel goes through the first stage of production, slicing. Rolls of sliced steel are cut into stator and rotor package laminations in our high speed presses with progressive dies. If required, cut laminations are heat treated to increase their electromagnetic properties. Steel laminates of 0,50 mm thickness are piled together and riveted and then sent to the winding shop. The rivet production in this shop is a small example of how GAMAK produces every part in-house. Fan cowl production is also one of the operations of the press shop. Cowls produced by smearing sheet metal suitable for deep drawing has its air circulation and connection holes opened and becomes ready for assembly on the motors.
Aluminium Injection And Foundry
In our Aluminium Injection and Foundry, billets are melted down in induction melting furnaces. All aluminium parts are molded under high pressure while press injections into rotor slots are done at low pressure. This allows the molten aluminium poured into the slot to rise slowly, preventing porousness, cavity formations and breakage. Aluminium alloys are used for the production of motor cases, end caps, flanges and junction boxes of up to 200 size motors. With high pressure vertical and horizontal aluminium injection presses finely textured aluminium parts can be produced. After breaking off guides and cleaning, parts are sent to the semi-finished parts inventory to be used in assembly.
In the Machining Shop, shaft material drawn into circular bars are machined through six different operations to turn them into motor shafts. At the end of these operations rotors with shafts become ready for assembly. In this stage, cast iron casings and end caps are also machined. Our main principle here is to machine all sides of the part in one fixing. This way, when the parts are assembled together, there are no axial misalignment. All machining applied to the motor casing while preparing it for assembly is done in one fixing without moving the casing. Flanges and motor end caps are also machined in one fixing. Aluminium end caps and flanges are rapidly machined in automated conveyor-fed CNC machines. Parts ready for use are stored in semi-finished products inventory.
GAMAK is one of the very few electric motor companies that can produce its own enameled wire. Our own copper wire rolls are produced in our Wire Enameling section. 8 mm wire rod that we procure is first drawn into 2 mm and then lower. Copper wire fed into mini rolling mills working synchronously with the enameling machines are drawn into desired dimensions and enameled simultaneously. Copper wires enameled with two different varnishes are produced to C class, ie 200° C. A critical component of the quality of our motors is that we can produce the enameled copper wire that forms the heart of a motor in-house. The 6 tons of enameled round copper wire produced in this facility is completely used in GAMAK motors.
At the first stage of winding, insulation material purchased as rolls is sliced according to stator package sizes. Stator packages that arrive at the winding shop receive slot insulation material and become stator cores ready for winding. Automated winding machines are set up and programmed according to the specifications of the motors to be wound. Coils formed by these machines are moved to the stator core with transfer tools and put into stator slots along with slot covers. All motors regardless of size receive phase insulation material. Wire connections and cables are connected, connections are covered with tubing. Winding heads are sewn together and the whole stator is tested. Large motors and motors requiring special winding are wound by hand. Coils prepared in winding machines are laid into stator slots by manual insertion. Cables are welded onto the coils and the wound stators are tested. Stators are then dipped into H class varnish and are baked to dry and harden.
Dynamic balance of GAMAK electric motors are done according to mechanical vibration class described in DIN Euronorm complete with an half-size wedge at the end of the shaft. All assembled motors are measured for resistance, insulation tests are done and run at no load to measure and record current values. After the wound stator is pressed into aluminium casings CNC lathes prepare end cap rabbets. After the balanced rotor with mill is assembled, caps are fixed and the terminal connections are made and the terminal box mounted. GAMAK Electric Motors are painted grey as standard (except IE3 class). Fans and fan cowls are mounted on the motors and their nameplates are prepared. Engraved nameplates contain the original values of the motor.
Our Custom Manufacturing section is capable of manufacturing products with different specifications that meet the needs and requirements of industrial companies. Due to the flexible structure afforded by being able to produce all parts required for the manufacture of electric motors, we can produce special purpose motors that other companies either cannot or are unwilling to produce. Stainless steel shafts, special copper injection casings, motors that are above the standart production power ratings, etc. Can all be easily produced in our Custom Manufacturing section.
Repair & Maintenance
In this section where we conduct repair and maintenance of all motors produced by GAMAK, our products that our laboratory finds faulty or products that fail over time are repaired by our skilled workers. All units are tested in the laboratory again until they return to a regular healty working state and are shipped to the customer following approval.
An important aspect of continuity of production is the design bureau and our die shop. Design and drafting of continuously improved motors are done in the design bureau. After technical drawings are drafted wooden models for cast iron parts are produced in our model workshop. All dies used in our manufacturing are produced in our well-equipped die shop. Segmented progressive sheet metal cutting dies used in the lamination presses are produced from tungsten carbide material. Casing, caps, flange and terminal box dies used in the aluminium injection are produced here. Injection dies for plastic products manufactured inhouse are also produced in this die shop.
Our test and development laboratory which ranks among the best in Europe where load testing up to 900 kW motors can be done, newly designed motors or motors that have had their electrical ratings changed are tested at nominal power. Motors are run until they reach thermal equilibrium and their current values, input power, losses, power factor, efficiency, momentum, temperature rise and similar values are measured, locked rotor tests are conducted and a test certificate with all tested values is produced. Speed – momentum – current graphs are produced. Motor noise levels are measured in the quiet room. Electronic start relays of monophase motors are also tested. Laboratory section also serves as a center for R&D work.