Process design and evaluation for the automation of interphase insulation for distributed windings

Abstract

In the production of electrical machines based on the pull-in technology, the stator, with a share of 35% of the total costs, is the most expensive component in the electric motor and offers a variety of automation possibilities of the process. The insertion of the phase insulation paper into the stator winding head is mostly done within manual assembly stations. This process step offers automation potential for the production of a process-safe phase insulation. The aim is to develop and qualify an automated application method. Therefore, the process is redesigned by the idea of a robot-supported application of the phase insulation with a spray system. For feasibility studies, a robot-supported spray insulation system is designed, built and subsequently integrated into a robot cell. Using several test setups, different process tests are carried out to check the application possibilities of sprayable insulation materials as phase insulation in the stator winding head. In particular, the effects of the various process parameters on the indentation strength of the new insulation materials are being investigated using laboratory tests.