• Hairpin windings provide a very high copper slot fill factor in an eMachine resulting in higher power to weight ratio.
  
  
• Our Wafios CNC Spring and Wire Forming System imports 3D geometries to manufacture the majority of hairpin & winding designs without the need to change tools as the basic tooling is independent of either wire cross-section or hairpin geometry.
  
  
• The system includes all necessary tools for Hairpin manufacturing, also covering bus bars, phase leads, neutrals, star connections, and jumpers made of rectangular wire material. This includes aluminium and materials with novel coatings. The system can also be used to form battery busbars and inductors.

• Continuous hairpin winding designs offer a reduced overall axial length of the eMachine couple with a reduction in the winding losses as the overhang of the windings from the stator lamination is reduced. When coupled with a reduction in the number of welds, as there are no open tails, the ability to manufacture continuous hairpins is essential for the DER Winding Centre of Excellence for trialling new technologies.
  
  
• The NWS needle winding system is a six-spindle winding system capable of winding both
  • round (0.4mm to 3.5mm diameter) and
  • rectangular (1 x 5mm to 3 x 10mm cross-section) wires.

including aluminium and materials with novel coatings.

• The production line is capable of the roll-up, compression of the double-layer wound mat, insertion, and expansion of the double-layer wound mat into the stator lamination stack.

• Concentrated windings provide a singular coil wound around a stator tooth or bobbin. This is a common method in the production of eMachine stators and the coils can be manufactured quickly. The result is a minimal coil overhang length from the stator lamination stack.
  
  
• Therefore, it is natural that our NWS needle winding system has the capability to produce concentrated wound coils at wire diameters range of 0.7mm to 2mm.
  
  
• Similar to all our other winding processes, it will be suitable for both copper and aluminium with novel insulation coatings.

• Further rotor topologies are possible at the Winding Centre of Excellence, such as wound rotors.
  
  
• The NWS needle winding system can directly wind the inside or outside of grooved rotors.
  
  
• The various coil winding materials and coatings are suitable for this application with the addition of rotor mounting devices and basic holders.

• In addition to conventional round and rectangular wires, newer coil winding technologies for novel motors can be trialled. Axial coil forming is possible on our Wafios CNC Spring and Wire Forming System.
  
  
• Axial flux motors are becoming increasingly explored for automotive and aerospace applications due to their inherent higher torque and compact forms. The axial direction (rotational axis) of magnetic flux, rather than radially, results in a much shorter length of the rotor.
  
  
• The Wafios equipment can wind bespoke inductor cores due to its flexible control systems.

• Distributed windings form the bulk of eMachines now manufactured. The Aumann NWS needle winding equipment will be fitted with a manipular arm to allow the winding of distributed coils with up to 24 wires in hand. This will be able to provide bespoke distributed windings for prototypes or early phase production.