There are several advantages of automatic winding and inserting cells compared to stand-alone machines.
First of all the improved quality of the wire is wound directly into the insertion tooling. There is no risk of wire damage or deformation of the coil form during manual transfer as on a stand-alone machine.
Strong machine efficiency.
By combining several winding spindles with one inserter, the machine usage is much higher than on stand-alone equipment. The insertion tooling is divided in a lower part, located in the inserter and upper parts, that are transferred between the winders and the inserter. Instead of one or two stators a minute, a automatic wind/insert cell can produce a stator every 12-15 seconds.
Higher labor efficiency.
One operator can handle several machines or even a complete line if equipped with automatic load/unload units and a conveyor system. The initially higher machine invest can quickly be recovered by saving labor cost.
With our patented winding technology the WWME can wind distributed or non-distributed coils (also known as split phase and non-split phase winding). The waves are formed directly during the winding process which saves space and guarantees an optimal winding result.Winding of parallel wires is done with our twist-free system which improves insertion quality and ensures maximum slot-fill-factors.
Over the last years we have worked closely together with our customers to develop improvements resulting in an even higher quality of the product. Common problems of other alternator winding and inserting systems are: closing wedges that don't stay in position, lead ends that are in a random position and winding heads with randomly distributed wires. With the WWEM these problems belong to the past. Wedges are all in the same adjustable height, the lead ends go straight up and the wires of the winding heads are parallel (fanned-out) to ensure max. quality in the end forming process.
For high efficiency stators we offer the WWEM 1-F1 with an integrated intermediate forming press. The stator stays in the turntable with closed cuff support the whole time during the phase by phase insertion process, instead of releasing it every time for the transfer to the forming station. This is another small detail that improves quality greatly.
Loose Tooth / Bobin Winding
As the demand for higher slot-fill-factors reaches the limits of conventional winding/inserting technologies, more and more motor makers start wind directly on the single stator teeth that are assembled afterwards or bobbins that are assembled into segmented stators. We offer winding and assembly solutions with or without inter-coil connections. To ensure a maximum fill-factor, the wires are exactly positioned to prevent the problem of twisted wires.