Fast Agile Copper Turns and Robotic Magnet placement (FACTOREM)

该项目将开发优化的制造工艺和技术，以适应中低批量电机的生产。在大批量生产中使用的许多工艺需要大量的资本投资，而这些投资在较小的产量下永远无法收回，而且劳动密集型手工机器太昂贵，无法达到高产量。为了打破这一明显的僵局，将开发一系列自动化进程，这些进程将大大降低成本，使许多现有应用程序充分发挥其潜力。重点关注的三个领域是线圈绕组、磁体放置和转子碳纤维捆扎。之所以选择这些流程，是因为在我们从更多的人工小批量技术迁移的过程中，它们提供了最大的降低成本和供应链价值的潜力。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征是，可以将资本设备部署到不同的应用程序，以便可以摊销前期成本的机器数量超出了单一应用程序的范围。水下自主机器人推进和建筑设备的现有产品以及紧急城市空气流动性(UAM)推进产品将作为控制项目，以确保这些工艺可以应用于这一范围。该项目将由Magonomatics、GTR和华威制造集团(WMG)进行，WMG是绕组卓越中心。Magonomatics拥有一系列小批量制造的产品，并将带来他们现有的经验和技术以及最终用户的要求。GTR是碳纤维制造领域的专家，将开发所需的转子捆绑工艺，以从这些材料获得一流的性能。WMG将带来他们的线圈绕组专业知识，并利用他们在设施中对设备的重大投资来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.