Winding Machine for Automated Production of an Innovative Air-Gap Winding for Lightweight Electric Machines

This paper presents a newly developed winding machine, which enables an automated production of stator-mounted air-gap windings with meander structure. This structure has very high accuracy requirements. Therefore, automation is realized by the interaction of 15 actuators and a compound construction with 13 degrees of freedom. The programming works with discrete open-loop motion control to generate the kinematics. Above all, a flexible prototype of the winding machine is developed, manufactured, and tested for a motor with external rotor. Finally, experimental results of the developed automation for air-gap windings with meander structure are presented.