Processes 2018-04-02T20:07:49+00:00

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PROCESSES AND PRODUCTION CONCEPTS AS REQUIRED

risomat covers the entire process of manufacturing stators and rotors

Thanks to its in-depth expertise,  risomat masters the complete process chain for the production of stators and rotors.

Under the aspect of increasing automation and increasing quantities, the processes are constantly being further developed and optimized.

Process Steps

DESCRIPTION

During the packetize process the individual insulated sheets are stacked to a stator and then connected to each other by various methods such as welding, gluing or clamping. When stacking appropriate measures must be taken to ensure the parallelism and eccentricity of the stator.

TYPES

Paketise Machines

  • vertical and horizontal types

  • manual or automatic stacking

APPLICATIONS
  • generators

  • big motors

  • servomotors

  • rotors

ADVANTAGES
  • technical design which guarantees a perfectly stacked stator package

  • fast tool change

  • flexible use and parameterizable

DESCRIPTION

During the isolating process isolating materials are used in different geometries accurately in the stator to isolate the coils against the stator high voltage resistant. Here, different insulating materials are used, which must be reliably introduced into the grooves.

TYPES

Insulating machines for the following insulation geometries

  • U- Shape

  • V- Shape

  • S- Shape

  • B- Shape

  • Y- Form

  • box type

APPLICATIONS
  • inside grooved stators

  • external rotor

  • all-purpose motors

  • rotors

  • hairpin stators

  • flat pack

ADVANTAGES
  • easy ergonomic operation

  • fast tool change

  • flexible applicable and parameterizable

  • constantly high embossing quality

  • isolation of loose stacked sheets

  • recording the process parameters

  • automatic reloading of the insulating material

DESCRIPTION

The flyer, linear or needle winding method is used for winding coils for stator and rotor windings. risomat masters all the aforementioned winding methods. Which method is used project-specifically, is decided together with the customer on the basis of technical and economic criteria’s.

TYPES
  • flyer winding (horizontal/vertical

  • linear winding

  • needle winding

APPLICATIONS
  • distributed windings

  • concentrated windings

  • pulled coil

  • rotor windings

  • windings of externally grooved stators

ADVANTAGES
  • mastery of all common winding methods

  • selection of the most suitable winding method for the corresponding application

  • flexible applicable and parameterizable

  • junction-free winding

  • automatic wire change

  • automatic tool change

DESCRIPTION

The introduction of the pre-wound coils into the stator slots is accomplished by means of the risomat pull-in technology. Here, the objective is to collect the coils without damage in the grooves and to achieve the highest possible degree of filling. When pulling in the grooves are additionally closed automatically by means of slot wedges.

TYPES
  • inserter (vertical)

  • inserter with integrated slot wedges machine

  • inserter combined with a winding machine

APPLICATIONS
  • single-layer and two-layer windings

  • pre-packaged stators

  • loose sheets

  • big motors

  • generators

  • pump motors (PVC insulated wires)

ADVANTAGES
  • high groove fill factor (> 50%)

  • short winding head

  • insert loose stacked sheets

  • mild insertion process by moving blades

  • easy quick changeover

  • automatic tool change

DESCRIPTION

The drawn-in coils must be shaped or compacted in the region of the winding head, so that the subsequent pulling-in process can be carried out, or after the preforming the bonding or after the final shaping the bandaging can be carried out.

TYPES
  • intermediate forming

  • pre forming

  • final forming

APPLICATIONS
  • traction motors

  • pump motors (PVC insulated wires)

ADVANTAGES
  • high forming quality

  • fast tool change

  • flexible applicable and parameterizable

  • easy process-safe forming concept

  • automatic tool change

DESCRIPTION

In stators for generators and PSM machines, the sheets are skewed, so that the voltage or torque ripple can be kept as small as possible. risomat has developed a process whereby the stators can be set and welded after all coils are inserted.

TYPES
  • skewing-welding (horizontal)

  • forming-skewing-welding (vertical)

APPLICATIONS
  • generators

  • stators for PSM machines

ADVANTAGES
  • high flexibility due to programmability of all setting parameters

  • fast tool change

  • exact rectilinear setting of the stator laminations

  • exact concentricity of the stator bore

  • integration of several machining processes

DESCRIPTION

The coil lead, which is laid on the winding head, must be insulated by means of insulating hoses against high-voltage and partial discharge. risomat has enormously optimized and streamlined this manual operation with the help of an ergonomic manual workstation, as well as a wiring template and a tube dispenser. The isolated leads are stored and fixed on a patented stator workpiece carrier.

risomat is currently working on the complete automation of the sliding of the insulating hoses.

TYPES
  • manual workstation

  • stator workpiece carrier

  • tube dispenser

APPLICATIONS
  • stators of all pole numbers

ADVANTAGES
  • ergonomic hand or standing workstation

  • storage and fixation of the isolated discharge on the stator workpiece carrier

  • storage and fixation of the isolated connections on the stator workpiece carrier

  • working on the complete automation of this process

DESCRIPTION

The coils of the individual phases must be insulated from each other in the winding head against high-voltage and partial discharge. risomat has enormously optimized this manual activity with the help of an ergonomic manual workstation. risomat is currently working on the complete automation for introducing the phase separators.

TYPES
  • manual workstation

  • dispenser of phase separators

APPLICATIONS
  • stators of all pole numbers

  • single and two layer winding

ADVANTAGES
  • ergonomic hand or standing workstation

  • working on the complete automation of this process

DESCRIPTION

The coil leads, which are stored on the stator workpiece carrier, must be connected in star or delta connection. In order to make this process reproducible, risomat has enormously optimized and streamlined a method based on the use of a wiring template. risomat is currently working on the complete automation of the interconnection.

TYPES
  • manual workstation

  • wiring template

APPLICATIONS
  • stators of all pole numbers

  • single and two layer winding

ADVANTAGES
  • ergonomic hand or standing workstation

  • reproduceable and exact installation of the coil leads by using a wiring template

  • automatic contacting with the support of the fixed leads in the wiring template

  • working on the complete automation of this process

DESCRIPTION

After interconnection, the coil terminals are contacted, preferably by the hot-crimping method.

TYPES
  • automatic hot-crimping machine

APPLICATIONS
  • stators of all pole numbers

  • single and two layer winding

ADVANTAGES
  • fully automatic process

  • recording of all relevant process parameters

  • automatic electrode measurement

DESCRIPTION

The coils in the winding head on the switching and non-switching side are laced with a cord. This ensures that, on the one hand, the interconnected leads abut compactly on the winding head and, on the other hand, no loose wires protrude for impregnation.

TYPES
  • lacing machinery – single

  • lacing machinery – double

APPLICATIONS
  • stators of all pole numbers

  • single and two layer winding

ADVANTAGES
  • high flexibility through programmability of all setting parameters

  • run control based on an electronic cam disc

  • fast tool change

  • automatic package length measurement

  • pull regulation of the lacing cord

  • automatic fastening

DESCRIPTION

After lacing and final forming, when the stator is prepared for impregnation, the electrical testing of the incorporated winding and insulation system is performed. The following measurements are used: resistance, inductance, impulse voltage, partial discharge, high voltage, insulation resistance and rotating field.

TYPES
  • manual workstation

  • automatic measurement system

APPLICATIONS
  • stators of all pole numbers

  • single and two layer winding

ADVANTAGES
  • integration in the production process

  • automatic stator handling and contacting

  • automatic test procedure

  • automatic evaluation of measured values and archiving