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A manipulator robot picks up a hairpin wire and inserts it into a stator core during the traction motor stator assembly.

Traction Motor Stator Assembly Process

The THORS Traction Motor Stator Assembly Process course is designed to provide learners with a more in-depth understanding of how the traction motor stator for Electric Vehicles (EVs) is assembled in both the front end and back end. Ready to take the next step? Explore the course details and see everything we’ve packed into this program!

Learning Hours: 2

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Course Description

The THORS Traction Motor Stator Assembly Process course explains the various processes in front end assembly and the back end assembly of a stator that is used in a traction motor. The course progresses through the processes beginning with basic copper wire forming and bending before being inserted into the stator laminates. Then, the wires are welded, receive a varnish application and epoxy bath, and the final components are added to the stator. Finally, the learner is introduced to the electrical testing methods that are completed before the stator can be shipped out of the assembly plant.

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Who will benefit from this Traction Motor Stator Assembly course?

Sales, Purchasing, Manufacturing Engineering, Quality, and Design Engineering

Course Classification

This manufacturing course by THORS eLearning Solutions covers understanding and application of the covered topics.

*THORS uses the Bloom’s Taxonomy Methodology for our course development.

Certificate Awarded for Traction Motor Stator Assembly Process

Example of certificate awarded upon successful completion of the course.

*upon successful completion

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Learning Objectives

  1. Understand the wire straightening, stripping, and cut-to-length processes.
  2. Learn how a wire is bent into a specific shape that is used in the stator.
  3. Develop knowledge of the slot liner forming and various wire insertion methods.
  4. Recall the steps taken during the end turn preparation.
  5. Visualize how the strain relief bracket, connection ring, and neutral bar are installed.
  6. Understand how epoxy and varnish are applied to the stator windings.
  7. Differentiate between the various electrical tests.
A copper wire is laser ablated to prepare it for the weld process that occurs during the traction motor stator assembly.
THORS Traction Motor Stator Assembly Process Course Image

Table of Contents

  1. Stator Front End Assembly
    1. Wire Forming
      1. Mechanically Straightening
      2. Wire Stripping
        1. Mechanical Wire Stripping
        2. Laser Ablation
      3. Cut-to-Length
    2. Wire Bending
      1. CNC Wire Forming
      2. Die Forming
      3. Servo Bending
      4. CNC Servo Bending
    3. Stator Stack Fabrication
    4. Slot Liner Forming
    5. Wire Sorting
    6. Wire Insertion
      1. Auto-Indexing Wire Insertion
      2. Robotic Wire Insertion
      3. Wire Basket Weave Insertion
      4. Phase Lead Insertion
    7. End Turn Preparation
      1. Pressing
      2. Spreading
      3. Twisting
    8. Phase Paper Installation
  2. Stator Back End Assembly
    1. Trimming
    2. Welding
      1. Tungsten Inert Gas (TIG) Welding
      2. Laser Welding
    3. Strain Relief Bracket Installation
    4. Varnish Application
    5. End Turn Epoxy Application
    6. Connection Ring and Neutral Bar Assembly
    7. Final Curing
    8. Electrical Testing
      1. Hi-Pot Test
      2. Surge Test
      3. Resistance Test
      4. Capacitance Test
    9. Final Inspection and Packaging
      1. Final Dimensional Measurement
      2. Visual Inspection and Auditing
      3. Rust Preventative (RP)
      4. Packout

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