Schaeffler Germany

Linear Winders from ELMOTEC STATOMAT

Linear winding technology for the production of concentrated windings

The linear winding process is preferably used for small components with a high number of turns and small wire diameters or for rotationally symmetrical segments with very large wire diameters. The technology is also suitable for applications where high wire quality after winding, very good heat dissipation and flexible interconnection types are required.

The need for ever higher slot fill factors, combined with a compact design, is pushing conventional winding and insertion technology to its technical limits. More and more motor manufacturers, especially for automotive applications in hybrid modules, have therefore started to directly wind individual stator teeth or coil carriers and then fully automatically assemble these segmented stators.

Highlights of the linear winding technology
  • Coil winding with layer accuracy
  • Maximum winding speed up to 1,000 rpm
  • Air coil, double segments, flat wire
  • Can be completely integrated into an automatic production line
  • Measurement of wire elongation and wire force,
  • Integrated wire clamping
Maximum precision

To achieve a maximum slot fill factor, it is particularly important to position and fix the wires precisely in the spool body. To ensure even laying of the wire in the winding space, the axis of rotation and laying axis must be precisely aligned during the entire winding process.

Positioning and laying accuracy

With the automatic process developed by Schaeffler ELMOTEC STATOMAT, we can ensure the highest positioning and laying accuracy. This prevents wire crossings and damage to the wire. In addition, our process ensures that the so-called “belly” of the winding remains minimal even at the highest revolutions (up to 1,000 revolutions per minute).

The versatile linear winding technology is ideally suited for the production of precision windings.

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Things to know about the linear winder from ELMOTEC STATOMAT

Full automation possible

Linear winders in electromobility

Maximum fill level, compact winding design and highest quality – these are the challenges in the production of efficient hybrid modules. In order to make the maximum use of the small installation space, high-precision linear winding technology is used. The required quantities can only be realised by using up to six winding axes and a high degree of automation.

  • Cycle time of 24 seconds at 1,000 rpm
  • Wire feed adjustment, wire brake, wire force measurement
  • Air coils and flat wire option
Linear winder for the production of servo motors

Servo motors are used wherever high power densities are required. Typical fields of application are power steering systems, drives for machine tools or industrial robots. The production and subsequent assembly of the coil bodies can be flexibly automated according to customer requirements.

  • Integrated inspection for checking the winding structure
  • Integrated stripping unit for wire ends (optional)
  • Integrated joining station for assembling the segments (optional)
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.
Discover more automatic winders from ELMOTEC STATOMAT

The portfolio of winding machines includes flyer winding, twist free winding, wave winding, linear winding and needle winding. We decide which winding machine is best suited based on individual customer requirements.

Innovative winding technology for the production of compact electric motors with maximum efficiency is a decisive building block for sustainable drive solutions in industry and e-mobility. With sophisticated automation solutions, these drives can already be realised today

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Our partners and Cooperations
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.