Schaeffler Germany

Manufacturing process Winding Assembly

Assembly processes for round wire and flat wire coils

In the indirect winding process of the round wire insertion technique, the winding is first produced by winding the individual wires as an air coil onto a special tool or template. The windings produced by this process are then transferred to a pull-in station for assembly.

The insertion process takes place in three phases. First, the tool enters the stator. This is followed by the extension of the insertion tool to begin insertion of the coil into the slot. After the wires have entered the slot, a cover slide is inserted to prevent the wires from being pushed out of the slot after the retraction tool has been extended. Finally, the coil is inserted.

Special features of the winding assembly

In the innovative flat wire wave winding technique, the winding is first produced in the form of a continuous “mat”. After the forming process, the wound mat is transferred or “rolled in” into a special tool. Once the transfer process is complete, the winding is fixed in the tool and transferred to the insertion station. The insertion or expanding process in flat wire wave winding is not axial, but radial.

The process of winding assembly is crucial for the quality of the electric motor. Only when the winding has been mounted in the stator slots without damage can a long running time be achieved.

Once the insertion or expansion process is complete, the winding head is finally expanded so that there can be no obstruction when inserting the cover slides. The cover slides act as an additional insulation layer and fix the winding securely in the stator slot.

When inserting or expanding the winding into the stator slots, the decisive quality features are a high ratio of wire to slot area (fill factor), winding heads that are as short as possible and gentle processing of the winding wire.

Production Know-How

Further information on the subject of winding assembly

  • Coordinated process steps
  • Highest precision and quality
  • Winding assembly for round and flat wire windings
Insertion technique for round and flat wire applications

In the classic round wire insertion process, the ideal coordination of the winding, insertion and forming processes is crucial. This is the only way to achieve maximum filling degrees without wire damage.

With flat wire wave winding, the winding is not “inserted” axially into the slots but “expanded” radially. ELMOTEC STATOMAT’s patented process revolutionises manufacturing technology and enables completely new motor designs, completely without the use of special pins and a drastic reduction in welding spots.

Do you have any questions about our equipment or the services we offer?
Our experts will be happy to advise you on questions relating to our winding technology or special manufacturing processes for stator production.
Other manufacturing process steps

The ideal interaction of all manufacturing processes is the prerequisite for the production of high-quality and durable stators. At Schaeffler ELMOTEC STATOMAT, we offer processes that are optimally tailored to the needs of our customers. From interlinked individual machines to turnkey solutions.

Innovations in winding technology make a decisive contribution to a sustainable future. Efficient drives ensure CO2 savings in operation and less raw material consumption in production.

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ELMOTEC STATOMAT maintains a close cooperation with renowned suppliers and strong partners. These cooperations allow our systems to score with the most economical components for precision, quality and durability.