Fast Agile Copper Turns and Robotic Magnet placement (FACTOREM)

该项目将开发针对中小批量电机生产进行优化的制造工艺和技术。大批量生产中使用的许多工艺都需要大量的资本投资，而这些资本投资永远无法在小批量生产时收回，而劳动密集型的手工制造机器又太昂贵，无法实现大批量生产。为了打破这种明显的僵局，将开发一系列自动化流程，这将显着降低成本，使许多现有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缠绕、磁铁放置和转子碳纤维绑带。选择这些流程是因为当我们从更多的手动小批量技术迁移时，它们提供了降低成本和供应链价值的最大潜力。该方法将使用通用机器人技术以及创新工具和运动控制软件的应用。该方法的一个关键特征是资本设备可以部署到不同的应用程序，这样可以摊销前期成本的机器数量就可以扩展到单个应用程序之外。水下自主车辆推进和施工设备中的现有产品以及新兴的城市空中交通（UAM）推进产品将作为控制项目，以确保该工艺可以在该范围内应用。该项目将由 Magnomatics、GTR 和华威制造集团 (WMG) 的绕线卓越中心承担。 Magnomatics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 是碳纤维制造方面的专家，将开发使这些材料达到一流性能所需的转子绑扎工艺。 WMG 将带来其线圈绕制专业知识，并利用其工厂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.