Research and development have always played a key role at SycoTec. Which makes it a very special pleasure when young, next-generation talents are able to put their research into practice with us. One of our next-generation employees is one such talent. Having successfully completed his thesis entitled “Development of a winding machine for electric motors using air gap winding technology”, he started out at as engineer in the Motor Elements section of the Development department. His first task: to put his elaborated theory into practice.
Great talent meets great demand
Electric motors with air gap windings are noted for a range of advantages. These include the total absence of cogging torque and thus better control behaviour in positioning operations. Reduced mechanical vibrations lead to much quieter running. In brief: When it comes to maximum motor control precision, nothing beats air gap windings. And the demand for them is rising. In order to be able to manufacture large quantities of the required stators, our employee developed a winding machine based on his designs. The finished device will be used in series production starting in April 2016.
Automatic, flexible, affordable
Compared to how air gap windings used to be made, this automated winding machine does away with 7 out of 10 manual work steps. Nevertheless, a comparably high copper filling factor is achieved.
It is possible to make a large number of different stator windings. To do so, a suitable winding body must be clamped in position and the desired wire threaded in. Important parameters such as the number of pole pairs, the type of air gap winding, stator length and diameter, the number of windings and circuit type can be flexibly configured.
Another advantage is the use of simple coil carriers instead of the conventional carriers with separating bars. The resultant savings can amount to up to 10 percent of overall production costs.
Together with the reduced work effort, the new winding machine allows us to achieve faster, more efficient and more affordable production – especially for sophisticated drive units. Advantages we would like to pass on to our customers.
