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Utilizing cable winding and industrial robots to facilitate the manufacturing of electric machines
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.
2013 (English)In: Robotics and Computer-Integrated Manufacturing, ISSN 0736-5845, E-ISSN 1879-2537, Vol. 29, no 1, 246-256 p.Article in journal (Refereed) Published
Abstract [en]

Cable wound electric machines are used mainly for high voltage and direct-drive applications. They can be found in areas such as wind power, hydropower, wave power and high-voltage motors. Compared to conventional winding techniques, cable winding includes fewer manufacturing steps and is therefore likely to be better suited for automated production. Automation of the cable winding production step is a crucial task in order to lower the manufacturing costs of these machines. This article presents a production method using industrial robots for automation of cable winding of electric machine stators. The concept presented is validated through computer simulations and full-scale winding experiments, including a constructed robot-held cable feeder tool prototype. A cable wound linear stator section of an Uppsala University Wave Energy Converter and its winding process is used as a reference in this article. From this example, it is shown that considerable production cycle time and manufacturing cost savings can be anticipated compared to manual winding. The suggested automation method is very flexible. It can be used for the production of cable wound stators with different shapes and sizes, for different cable dimensions and with different winding patterns.

Place, publisher, year, edition, pages
2013. Vol. 29, no 1, 246-256 p.
Keyword [en]
Stator winding, Automated production, Industrial robot, Electric machine assembly, Powerformer, Wave energy converter
National Category
Engineering and Technology
Research subject
Engineering Science with specialization in Science of Electricity
Identifiers
URN: urn:nbn:se:uu:diva-187001DOI: 10.1016/j.rcim.2012.06.005ISI: 000310116400021OAI: oai:DiVA.org:uu-187001DiVA: diva2:573757
Available from: 2012-12-03 Created: 2012-12-03 Last updated: 2017-12-07Bibliographically 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. 82 p.
Series
Digital Comprehensive Summaries of Uppsala Dissertations from the Faculty of Science and Technology, ISSN 1651-6214 ; 1608
Keyword
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: 2018-01-12

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Hultman, ErikLeijon, Mats

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