EV Car Stator Assembly Line (2021)

EV Car Stator Assembly Line (2021)
Designed to produce stators with a height range of 100–210 mm and a diameter of 160 mm
Including manual, semi-automated, and fully automated operations
Cycle time: 86 s

Stations and Equipment

End Plate Sub-assembly (Gluing)
End plate Loctite gluing onto metal sheet stack and laser marking
Grob semi-automated assembly machine (2021)
Keyence laser

Stator Stack Preparation
Stator stack preparation (loading) and height measurement
7 metal sheet stacks with a height of 25 mm loaded on a rotating table

Slot Insulator Insertion
U-shaped paper insulator insertion
Grob automated assembly machine (2021)
Insertion of 48 “U”-shaped paper insulators

3x Winding Stations
3x copper wire winding stations, wire fed from barrels
Grob automated assembly machines (2021)
Maximum number of wires: 15

Insulation Tube Assembly and Cutting
6 manual stations for insulation tube assembly
1 cutting station connected via conveyor

2x Wire Pre-forming
2 automated wire pre-shaping stations
2T Kistler press

Phase Separator Assembly
6 manual phase separator assembly stations between coil assembly stations, connected via conveyor
1 rotating station for stator cradle rotation

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8x Stator Hot Crimping Preparation
8 manual stations for stator hot crimping preparation

2x Connector Hot Crimping
2 electric welding machines with force and current measurement
Lingl PZ5 welding machines (2021)

10x Final Forming Preparation
10 manual stator final forming preparation stations

Final Wire Forming
Wire shaping using a 2T Kistler press

2x Lancing
2 Grob automated stator lancing machines (2021)
Lancing for stator heights of 140 mm and 210 mm

Phase Separator Cutting Station
Teknomatik semi-automated stator lifting and pre-cutting machine

Stator Stack Skewing and Laser Welding
Automated skewing, laser welding, and laser marking
KUKA robot KR 250 R2700-2/FLR (2021)
TRUMPF TruDisk 4002 welding laser (2021)

End-of-Line (EOL) Electrical Measurement
Semi-automated stations for high- and low-voltage testing
ETL ATS 400 automatic test system
ZAW resistance measurement tester (2023)

Heat Shrink Tube Assembly
Prospertech semi-automated stations for heat shrink tube placement on wires

Stator Resin Impregnation
Automated Tecnofirma resin application and heating process
Includes:
1x induction heating zone
1x pre-heating zone
5x impregnation zones
2x infrared lamp zones
1x gelation zone
1x curing zone
Integrated Minimax firefighting system
KUKA robot KR 150 R2700-2/FLR (2021)