Introducing Robotized Stator Cable Winding to Rotating Electric Machines

Following environmental concerns and the rapid digitalization of our society, we are currently experiencing an extensive electrification and industrial revolution. High numbers of electric machines thus need to be assembled for varying applications, including vehicle propulsion and renewable energy conversion. Cable winding is an alternative stator winding technology for electric machines that has been utilized for such applications, so far in smaller series or in prototype machines. The presented work introduces the first concept for automated stator cable winding of rotating electric machines. This concept could enable higher production volumes of cable wound machines and a unique flexibility in handling different machines, in line with Industry 4.0. Robotized stator cable winding is evaluated here for five very different rotating machine designs, through simulations and analytical extrapolation of previous experimental winding results. Potential cycle time and assembly cost savings are indicated compared to manual and lower volume conventional automation, while it is not possible to compete in the present form with existing very high-volume conventional winding automation for smaller machines. Future experimental work is pointed out on handling larger winding cables and special machine designs, and on increased robustness and optimization.