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An updated cable feeder tool design for robotized stator cable winding
Uppsala University, Disciplinary Domain of Science and Technology, Technology, Department of Engineering Sciences, Electricity.
Uppsala University, Disciplinary Domain of Science and Technology, Technology, Department of Engineering Sciences, Electricity.
2018 (English)In: Mechatronics (Oxford), ISSN 0957-4158, E-ISSN 1873-4006, Vol. 49, p. 197-210Article in journal (Refereed) Published
Abstract [en]

We have previously suggested a method for robotized stator winding of cable wound electric machines and demonstrated the method successfully in full-scale experiments. The cable feeder tool used to handle the cable during the complete winding process is an essential component of this robot cell. To take the robot winding method to the next level, into an industrial product, require further developments regarding durability, independency, flexibility and implementability. In this paper, we present an updated cable feeder tool design. This tool is designed to be used in a robot cell for cable winding of the third-generation design of the Uppsala University Wave Energy Converter generator stator. In this work, three cable feeder tool prototypes have been constructed, experimentally evaluated and validated for the intended application. Key performance parameters are presented and discussed, including suggestions for further developments. We completed a durable, compact, high performance tool design, with fully integrated control into industrial robot controllers. The experimental results presented in this article are very promising and hence, the updated cable feeder tool design represents another important step towards an industrial solution for robotized stator cable winding.

Place, publisher, year, edition, pages
2018. Vol. 49, p. 197-210
National Category
Robotics Other Electrical Engineering, Electronic Engineering, Information Engineering
Identifiers
URN: urn:nbn:se:uu:diva-334553DOI: 10.1016/j.mechatronics.2018.01.006OAI: oai:DiVA.org:uu-334553DiVA, id: diva2:1159854
Available from: 2017-11-23 Created: 2017-11-23 Last updated: 2018-04-26Bibliographically approved
In thesis
1. Robotized Production Methods for Special Electric Machines
Open this publication in new window or tab >>Robotized Production Methods for Special Electric Machines
2018 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

A research project on renewable energy conversion from ocean waves to electricity was started at the Division of Electricity at Uppsala University (UU) in 2001. The Wave Energy Converter (WEC) unit developed in this project is intended to be used in large offshore WEC farms and has therefore been designed with large-scale production in mind. The concept has now also been commercialized by the spin-off company Seabased Industry AB.

An essential part of the UU WEC is the linear direct-drive generator. This thesis presents the pilot work on developing robotized production methods for this special electric machine. The generator design is here investigated and four different backbreaking, monotone, potentially hazardous and time consuming manual production tasks are selected for automation. A robot cell with special automation equipment is then developed and constructed for each task. Simplicity, reliability and flexibility are prioritized and older model pre-owned industrial robots are used throughout the work. The robot cells are evaluated both analytically and experimentally, with focus on full scale experiments. It is likely that the developed production methods can be applied also for other similar electric machines.

The main focus in the thesis is on robotized stator cable winding. The here presented robot cell is, to the knowledge of the author, the first fully automated stator cable winding setup. Fully automated winding with high and consistent quality and high flexibility is demonstrated. Significant potential cost savings compared to manual winding are also indicated. The robot cell is well prepared for production, but further work is required to improve its reliability.

The other three developed robot cells are used for stator stacking, surface mounting of permanent magnets on translators and machining of rubber discs. All robot cell concepts are experimentally validated and considerable potential cost savings compared to manual production are indicated. Further work is however required with regards to autonomy and reliability.

Finally, the thesis presents a pedagogical development work connected to the research on robotized production methods. A first cycle course on automation and robot engineering is here completely reworked, as it is structured around three real-world group project tasks. The new course is evaluated from the examination results, the students’ course evaluations and the feedback from the teachers during six years. The students greatly appreciated the new course. It is indicated that the developed teaching approach is effective in teaching both classical and modern engineering skills.

Place, publisher, year, edition, pages
Uppsala: Acta Universitatis Upsaliensis, 2018. p. 82
Series
Digital Comprehensive Summaries of Uppsala Dissertations from the Faculty of Science and Technology, ISSN 1651-6214 ; 1608
Keywords
Industrial robotics, Assembly automation, Large-scale production, Cable winding, Linear generator, Wave energy converter, Wave power, Engineering education
National Category
Engineering and Technology
Research subject
Engineering Science with specialization in Science of Electricity
Identifiers
urn:nbn:se:uu:diva-335504 (URN)978-91-513-0177-8 (ISBN)
Public defence
2018-02-02, Polhemsalen, Lägerhyddsvägen 1, Uppsala, 13:00 (English)
Opponent
Supervisors
Available from: 2018-01-12 Created: 2017-12-07 Last updated: 2018-03-07

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Hultman, ErikLeijon, Mats

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