Winding treatment manufacturing process
Once the winding has been produced using a round wire or flat wire technique and then mounted in the stator slots of the stack of laminations, the forming and lacing process steps follow, depending on the winding method selected.
- Intermediate and final forming
- Forming and roller burnishing of flat wire winding mats
- Lacing of winding heads
In the round wire insertion technique, the individual coil strands of the windings lie partially disordered and uncompressed in the slot after the insertion process. So that further phases can be inserted, as well as to increase the mechanical copper filling factor, the windings are expanded with the help of a forming machine and pressed into the slot base (intermediate forming). As soon as all phases have been inserted and the winding head has been fixed by so-called lacing, the final forming process takes place (final forming). The machine moulding thus ensures that the technical properties, in particular the filling factor and the final dimensions, are achieved.
Realisation of a lean manufacturing process through the elimination of complex and partly manual process steps with the flat wire wave winding.
With flat wire wave winding, the continuously wound mat is finally compressed in the forming process so that the individual wires can be inserted precisely into the insertion or “rolling tool”. A final taping and final forming of the winding heads is not required with the flat wire winding technique.
Further information on the subject of winding machining
- Low winding head height
- Greatly reduced number of welding points
- No additional fixing of the winding heads necessary
Due to the continuously wound winding mat, the number of welding points in flat wire wave winding is reduced enormously compared to conventional hairpin methods. Due to the omission of welding points, low winding head heights can be realised and thus the active length of the stator can be optimised.
With the patented wire bending method for the production of so-called “U-shapes”, the motor design can be optimally matched to the final assembly process of the busbars.
Optimally coordinated, lean processes ensure maximum quality and system availability.
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.
“With the full automation of flat wire shaft winding technology, we have made an important contribution to the next generation of highly efficient electric motors.”
Jochen Klee, Managing Director
Schaeffler ELMOTEC STATOMAT
