Fast Agile Copper Turns and Robotic Magnet placement (FACTOREM)

该项目将开发针对电机中小批量生产的优化制造工艺和技术。大批量制造中使用的许多工艺需要大量的资本投资，而这些投资永远无法在较低的产量下收回，而且劳动密集型手工机器太昂贵，无法实现大批量生产。为了打破这一明显的僵局，将开发一系列自动化流程，这将大大降低成本，使许多现有的应用程序能够充分发挥其潜力。重点关注的三个领域是线圈绕组、磁体放置和转子碳纤维绑扎。选择这些工艺是因为它们在我们从更多的手工小批量技术转移时提供了最大的成本降低和供应链价值潜力。该方法将使用通用机器人技术，并应用创新的工具和运动控制软件。该方法的一个关键特点是，资本设备可以部署到不同的应用程序中，这样，可以摊销前期成本的机器数量就可以扩展到单一应用程序之外。水下自动驾驶车辆推进和施工设备的现有产品以及新兴的城市空中机动性（UAM）推进产品将作为控制项目，以确保这些过程可以在此范围内应用。该项目将由Magnomatics，GTR和沃里克制造集团（WMG），卓越绕线中心。Magnomatics拥有一系列小批量制造的产品，并将其现有的经验和技术以及最终用户的要求。GTR是碳纤维制造的专家，将开发转子绑扎工艺，以达到这些材料的一流性能。WMG将带来他们的线圈缠绕专业知识，并利用他们的工厂对设备的重大投资进行工艺开发和验证。

This project will develop manufacturing processes and techniques that are optimised for low to medium volume production of electrical machines. Many processes used in large volume manufacture require significant capital investment that can never be recouped at lower volumes, and labour intensive, hand-made machines are too expensive to reach high volumes. To break this apparent deadlock a series of automated processes will be developed that will give significant cost reduction allowing many existing applications to reach their full potential. The three areas for focus are coil winding, magnet placement and rotor carbon fibre banding. These processes have been selected as they offer the largest potential for cost reduction and supply chain value as we migrate from more manual low volume techniques. The approach will use generic robotics with the application of innovative tooling and motion control software. One key feature of the approach is that the capital equipment can be deployed to different applications such that the volume of machines over which the up-front cost can be amortised is extended beyond a single application. Existing products in underwater autonomous vehicle propulsion and construction equipment as well as an emergent Urban Air Mobility (UAM) propulsion product will serve as control projects to ensure the processes can be applied across this range. The project will be undertaken by Magnomatics, GTR and Warwick Manufacturing Group (WMG), Centre for Winding Excellence. Magnomatics have a series of low-volume manufactured products and will bring their existing experience and techniques and end-user requirements. GTR are specialists in carbon fibre manufacture and will develop the rotor banding processes required to reach class leading performance from these materials. WMG will bring their coil winding expertise and leverage the significant investment in equipment at their facilities for process development and validation.