Inserting Machines from ELMOTEC STATOMAT
The insertion technique is a widely used process for the production of closed stators with distributed winding. Due to the high flexibility and good automatability, a wide range of stators can be produced economically with this process.
In the insertion technique, a winding is first wound into a transfer and insertion tool in an upstream process, usually with the flyer winding or a twist free winding station. It is then “inserted” or mounted into the stator slots using the inserting machine. The wound coils can be inserted either per phase or together. Once all the coils have been mounted with the help of the insertion machine, a cover slide is inserted to close the slot.
In order to produce stators with the highest possible filling factor with the winding and insertion technology, the individual process steps of winding, inserting and forming must interact optimally. The winding of the coils must take place as free of crossings as possible and be deposited precisely in the transfer and insertion tools. The inserting machine equipped with special tools must be designed in such a way that the wires can be inserted into the groove without jamming or damage. The subsequent forming processes ensure that all phases and layers are inserted and that the deck slides can finally be mounted without damage.
Thanks to many years of experience and patented process solutions in winding and insertion technology, the Schaeffler ELMOTEC STATOMAT insertion machines are capable of producing highly efficient stators with mechanical slot filling factors of up to 88%.
Our extensive portfolio includes insertion machines for semi-automatic individual production as well as insertion machines that are integrated into fully automatic production cells.
With in-depth know-how in the manufacture and subsequent assembly of the winding, we at Schaeffler ELMOTEC STATOMAT are able to realise the highest slot filling factors. The insertion machines can be configured as stand-alone machines or as a modular component of an agile manufacturing cell or fully automated production line:
Our extensive equipment portfolio, consisting of insulating machines, winding machines, moulding machines and lacing machines, completes the process chain for the production of stators.
„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