Proceeding for wiring integrated winding of segmented stators of electric machines

For Hybrid-, Fuel Cell- and battery cars in the future electric motors in a high volume production are required. In the production of these motors the manufacturing process wiring of the coils was indentified as a possible cost potential. The stator of permanent excited electric machines in single tooth technique consists of separate winded single teeth, joined with the cupreous bus bar. Hence a production process was developed, realizing winding of all single teeth without wire disruption using needle winding technology. Alongside the cost-intensive manufactured copper blanks could be replaced by a proceeding of integrated wiring, using an adept laying of the wire along the tracks of a wiring assembly. In the paper the developed proceeding for wiring integrated winding of segmented stators is presented and several specific advantages are discussed.