Winding Machines for Round or Rectangular Wire
Odawara offers segment winding solutions for both round and rectangular wire, along with for low volume/R&D production through to high volume manufacturing. Individual processing cells for each step are available as are fully integrated, automated lines.
Individual segments are fixtured and rotated to precisely layer magnet wire per customer requirements. Wound segments are aligned and pre-assembled in the required circular orientation, after which the bus bar is placed.
Enamel is removed and lead wires are routed to the necessary position and cut to length in the lead processing step. Lead wires are welded to the bus bar per customer requirements. Welded segment assemblies are placed in the stator housing and secured in place by shrink fitting.
Additional capabilities can be included per customer requests, including:
- Laser Part Etching
- In-line Part Inspection
- Electrical Testing, Individual Segments or Full Assemblies
Why Choose Segment Winding
Segment winding involves winding individual stator segments separately and then assembling them into a complete stator core. This method provides high precision, flexibility, and scalability, making it an excellent choice for complex stator designs and modern electric motor manufacturing.
Segment winding is ideal for your applications that require:
- High precision and consistent quality
Each segment is wound independently with tight control over wire placement and tension, helping achieve uniform copper density and repeatable results across production runs. - Greater copper fill factor and performance
Segment winding supports efficient wire layering and can improve copper utilization and electrical performance, which is especially beneficial for high-performance motors. - Adaptability to complex and varied part designs
Winding individual segments allows easier accommodation of different geometries, wire types, and specialized tolerances that might be difficult for other winding methods. - Better production scalability
Machines can be configured as standalone processing cells or fully automated integrated systems, supporting both R&D and high-volume manufacturing environments.
| Wire AWG: | 24 – 17 |
|---|---|
| Maximum Stack Height: | 0.5 – 4” |
| Number of Winding Heads: | 2 – 4 |
These are typical product sizes. The capability of the machines to manufacture each stator depends on a number of factors including end turn dimensions, winding pattern, bus bar design, etc. Please contact an Odawara sales representative with your unique requirements.
Products Manufactured with Segment Winding Machine Technology
Segment winding machines are used to wind individual stator segments that are later assembled into complete stator cores. Odawara offers segment winding solutions for both round and rectangular wire, along with low volume/R&D production through to high volume manufacturing with individual processing cells for each step or fully integrated, automated lines.
This technology is essential in manufacturing electric motors and components found in automotive and industrial applications, including servo motors and hybrid electric vehicle systems. Through our advanced segment winding solutions, manufacturers have increased production, enhanced quality, and achieved greater automation.
See the chart below for examples of products with an electric motor commonly manufactured with segment winding technology.
| Automobiles | HEV drive & generator, EPS, Various pump, etc. |
|---|---|
| Industrial, Medical Equipment | Servo motor, etc. |
Typical Stator BLDC Line Structure
STC
Core Load
BOW
Coil Wind
FIC
Align Segments
BUS
Case Shrink Fit
TIS
Place Bus Bar
TUF
Process Lead Wires
SIF
Weld Lead Wires
Electrical Test
Automation and Material Handling
Increase efficiency even further with automation and material handling solutions by Odawara Automation. Our services include:
- Material Handling
- Dunnage Load/Unload
- Automated Machine Load/Unload
- Robotic Systems
- Test Equipment
- Part Transfer Systems: Conveyors and Transfer Pallets
- Vision/Inspection Systems
- Quality System Integration: Manufacturing Operating Systems (MOS) and Manufacturing Engineering Systems (MES)
