Manufacturing cell for winding and assembling a segmented stator of PM-synchronous machines for hybrid vehicles

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.