Electrified Automation are working with organisations globally to apply its expertise and IP in e-machine manufacturing to a range of motor typologies and end user markets. Electrified Automation have developed a series of disruptive manufacturing processes and associated automated equipment from coil winding through to rotor assembly to enable its customers to accelerate their plans for electrification. This session covered how Electrified Automation are applying their processes in e-machine manufacturing and building a UK PEMD supply chain to support them.

1. AUTOMATING E-MACHINE MANUFACTURING
Driving the Electric Revolution –
Engage with… Electrified Automation
18 March 2021

2. Jim Winchester
Managing Director
Lloyd Ash
Founder, Innovation Director

3. Barriers encountered
Brought IPM technology
to off-highway market
Supporting global e-machine
manufacturing from the UK
Our Background
Electric Motors

4. To drive the world towards electrification
through our people, our ideas and our actions
Our Mission
Process Development Automation Equipment
Value Chain Software
E-machine Components

5. Todays Aims
Challenges we can help with.
If we can collaborate.
How to engage with us.

6. Our Customers
5,000 – 100,000 e-machines
per annum
Variation required in
motor production
Process development
& validation

7. Concentrated Coil winding
Challenges
• Flexibility in available equipment
• Cost to acquire in-house capability
• Copper fill factors

8. Winding Typologies
• On edge
• <10% corner swell
• Wire thickness ≥0.8mm
• On flat
• Round wire
Concentrated Coil winding

9. Typical methods
• Coil connections - Crimp & solder
• Coil insulation – Nomex paper
• Manual enamel removal
Wire jointing & insulation

10. Wire jointing & insulation
Solutions
• Ultrasonic welding with Busbars
• Automated enamel removal
• Plastic insulation moulding

11. Stator moulding
Common process
• Resin fill & cure
• Increased durability & thermal
performance
• Creates manufacturing bottleneck

12. Stator moulding
Production moulding process
• Takt time < 4 minutes
• Equivalent mechanical properties
• Reduction in assembly line size

13. Magnet placement
Magnetised
• Difficult to handle
• Reduction in process
Un-magnetised
• Easier to handle
• Magnetisation process required

14. Features
• Eliminate inverter calibration
• Infield serviceability
• Data analytics
• Integrated temperature sensor
Position Sensors

15. E-machine testing
• Voltage: 24 – 400VDC
• Power: 1 – 100kW
• Mechanical package with torque sensor
• Power analyser integration
• Power supply integration
Dyno Engineering

16. Dyno Engineering
• Hardware package
• Control package
• Support package
• Customisable solution
• Bespoke software
development
• Automated drive cycle
• Developed for
academia
• Plug & play kit
• Training & support
Validation Enterprise Academic

17. Value chain software
• Customer management
• Supplier management
• Machine utilisation
• Predictive maintenance

18. Engagement
Factory
performance
Operator
performance
Other
behavioural
KPI data
Gamification platform
Data input Results
=
Engagement,
Performance &
Productivity

19. Consultancy
Industry experience Ramp up strategy
Process development Product validation

20. AIMS Project
Stator concept
• Robotic cell
• 3.5 minute takt time
• Released Q3 2021 LCV2021

21. Component supplier
E-machine production Collaboration partner
Partners we need
New career

22. Thank you
Jim Winchester
jim.winchester@electrifiedautomation.com