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.
- 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
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.
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.
Things to know about the linear winder from ELMOTEC STATOMAT
Full automation possible
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
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)
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