Due to the increased electrification of automobile powertrains, a strong market growth for electric drives is expected. Therefore the current manufacturing processes of powerful electric drives need to be modified for high volume production. The main idea for a new manufacturing process for a segmented stator was to integrate the wiring into the winding process in order to omit some production steps. A new manufacturing cell was set up as a prototype for the realization of the alternative winding, wiring and assembling technique. Several concepts for positioning the teeth and for assembling it to a stator were studied and the most favored concept has been implemented. Now the feasibility of the modified process technologies can be demonstrated. It must be concluded, that the prototypically constructed manufacturing cell is suitable for the wiring integrated winding and the subsequent assembling of the stator. Important insights were gained from the manufacturing experiments and could be defined as design-rules for further studies. Nevertheless, it became clear that in order to achieve a reliable manufacturing process some adjustments have to be made concerning the wire path between the single teeth and the circular wiring assembly. Due to the wire not being fixed in this area, it shifts away from its ideal position during the assembling process. For this purpose it is necessary to suit the design of the single teeth to the manufacturing procedure and to give the wire an additional fixation.
Manufacturing cell for winding and assembling a segmented stator of PM-synchronous machines for hybrid vehicles
2012
5 Seiten, 12 Bilder, 8 Quellen
Conference paper
English
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