Flexible automation for the production of contactless power transfer systems for electric vehicles

The increasing electrification of the automotive power train leads to significant changes in automotive value chains, while sales potentials are still uncertain [1]. Due to their considerable advantages in regard to safety and convenience, contactless power transfer systems may be the basis for further increasing the customers´ acceptance for electrified vehicle concepts [2]. Increasing market acceptance will require high volume production concepts for contactless power transfer systems. Thus, the importance of automated assembly and manufacturing technologies moves into the focus. Especially the winding process of the HF-litz wire coil structures shows potential for further rationalization. Therefore, it is the aim of this paper to present flexible automation concepts for this process.