Robotic based Assembly of insulating Sleeves onto Winding Coil Ends of Electric Drive Stators

In the production of electrical motors based on the insertion technology, the stator, with a share of 35% of the total costs, is the most expensive component and offers a variety of automation possibilities. In the field of secondary insulation, the application of insulating sleeves onto the stator winding coil ends is usually carried out in manual assembly stations, even in highly automated production lines. This process is a tedious and cost-intensive manual activity. The developments presented in this work show an automated assembly approach for this production step. This invention is based on an industrial robot assembly station that, among other processes, applies commonly used insulation sleeves to the respective winding parts in the stator winding head. With an initial process analysis and the construction of a prototype machine, the basic suitability as an automatable process solution for the assembly of insulation sleeves is presented.