Twist free Winders from ELMOTEC STATOMAT
The increasingly stringent specifications with regard to energy efficiency lead to higher demands on motor design and motor control. To realise the demanding designs, efficient processes in the production of the stators are crucial. Coil winding technology plays a central role here. A winding design that is as compact as possible is the decisive factor in achieving the power density and the specified installation space.
- up to 30 parallel wires
- With or without coil connections
- Optimised copper fill factor
- Crossings can be realised in the winding head
- Compact and resource-saving winding
Twist free winders are used wherever the winding specification requires many parallel wires. Unlike the flyer winder, the wires do not cross each other, but are wound neatly next to each other. It is possible to work with significantly more parallel wires.
The winders of the TFW series make it possible to process up to 30 parallel wires. Here, a precision layer winding is created, which enables optimum results when inserting. In combination with the patented ELMOTEC STATOMAT insertion system, the fill factor to be achieved is maximised.
Twist free winding is ideal for applications where maximum efficiency is important.
Interesting facts about the ELMOTEC STATOMAT Twist free Winders
Optimised fill factor, also in series
The ELMOTEC STATOMAT twist free winders are characterised by their precision when winding many parallel wires. Together with an innovative wire clamping and the patented inserting process, optimised slot filling factors of up to 88% can be inserted in the series.
Another special feature is the possibility of winding with or without switching connections directly into the insertion tool or into a transfer tool. With our patented “wire rotating device”, targeted crossings can be created in the winding head to further reduce eddy currents (“proximity effect”). Together with the optimised copper filling factors, highly efficient electric motors can be produced with the stencil winding.
In the “double spindle” version with a multi-station rotary table that is automatically loaded and unloaded, as well as the integrated production and positioning of deck slides, nothing stands in the way of economical production. Even with a high variance in production, the template winding process is suitable. Thanks to automatic package height adjustment and optimised changeover times of the winding and insertion tools, economical cycle times can be realised.
With the twist free production of copper coils, highly efficient drives can also be realised with the use of traditional round wire. These are used as the main drive in an E-axis or as a flexibly switchable all-wheel drive.
- Fill factor up to 88%
- Twists in the winding head to reduce losses
- Use of traditional round wire
Due to the ever more stringent efficiency requirements, the demands on the production technology are also increasing. Traditional winding technologies reach their technological or economic limits when it comes to achieving the highest fill factors. By using twist free windings, high copper fill factors can be produced economically even with a high number of turns.
- Up to 30 parallel wires
- High number of windings possible
The portfolio of winding machines includes flyer winding, twist free winding, wave winding, linear winding and needle winding. We decide which winding machine is most suitable 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.
