Process for producing an electromagnetic subassembly for a magnetic levitation railway

A method of manufacturing an electromagnetic assembly in form of a stator packet of a long stator motor for a magnetic levitation train, said assembly including a sheet stack consisting of ferromagnetic material, and at least an additional component, said method comprising the steps of:

• providing a plurality of raw magnetic steel sheets;
• providing first apertures on upper sides of said sheets;
• providing second apertures on undersides of said sheets;
• stacking said sheets for providing said stack so that at least one first groove is formed in said stack by said first apertures and at least one second groove is formed in said stack by said second apertures, said second groove being intended to accommodate an elastically deformable electrical conductor and having a groove wall and a cross-section selected according to desired electromagnetic properties of said stack;
• inserting a cross-piece into the at least one first groove, said crosspiece sewing as an aid for mounting said electromagnetic assembly;
• forming said assembly from said stack and said component;
• positioning said assembly in a cavity defined by wall portions of a shaping tool;
• and then finishing said assembly by means of a pressure-gelation method, said pressure gelation method comprising the steps of providing a thermally hardenable mixture which comprises a duroplastic epoxy resin component and a hardener component;
• introducing said mixture into said cavity such that said mixture is introduced into cavities between said sheets so as to connect said sheets as well as surrounds said sheets, said stack and said assembly as a whole on all sides;
• heating said shaping tool;
• hardening or hardening out said mixture at least as long until removal of said assembly from said shaping tool, whereby in one single working step said sheets are connected together, said stack is connected with said at least one component, said wall of said at least one second groove is provided during introduction of said mixture into said cavity with a lining comprised of said mixture such that a mechanically effective groove results having an effective groove wall with a cross-section selected according to said conductor, said assembly is provided with final electrical, magnetic and/or mechanical properties and said assembly is completely surrounded with an anti-corrosion layer having a thickness which is selected by a spacing between said sheet stack and wall portions of said shaping tool.