The SciMo project advanced winding technology for high-performance electric motors through four work packages. It began by assembling a team of software and hardware experts to build a winding machine demonstrator. Regular meetings set weekly goals, and thorough documentation met funding requirements, ensuring a solid foundation for technical progress.
The motor technology was validated in motorsports with a lead customer. Offering 75% higher power density and material efficiency, the motors powered vehicles to win a major U.S. hill climb race and set an Australian track record, proving their value for demanding applications.
Central to the project was the development of a fully automated winding machine demonstrator (WM04).Upgrades included steel plates for rigidity, wire tension increased to over 500N, a pneumatic fixation system handling 650N, and grippers with 150N force. The software was revamped to leverage ROS2, enabling precise control of multiple actuators and two UR16.e robots, while true parallel planning accelerated the process. After additional process refinements, the machine was commissioned in February 2024, and successfully produced a first fully automated coil on a stator. At the end of 2024 winding costs of around 450€ per unit were archieved enabling an annual production volumes of 500–1,000 motors.
To ensure motor reliability, the project implemented a comprehensive quality management system. The MTC2 R7 Schleich motor tester was integrated to assess stators, performing surge voltage, partial discharge, resistance, and insulation resistance tests customized to specific designs. An End-of-Line test bench standardized final motor evaluations, checking magnetic flux, rotation direction, harmonics, and mechanical performance before shipment. Four development test benches allowed flexible testing under diverse conditions—like subzero temperatures and various cooling media—meeting specific customer requirements. In motorsports, testing with the lead customer spanned 500–1,000 km per motor, with only two early prototype failures among 50 drive sets, confirming durability. Aviation testing progressed toward flight clearance for a turbine-coupled generator, paving the way for future certifications such as ISO 9100 and IATF 16949, ensuring consistent quality and market readiness.
SciMo’s robotic automation matched manual precision, with software enabling flexible stator production and single-tooling for all phases. Delivering lighter motors with 75% better efficiency, it set a new standard for motorsports, aerospace, and industrial applications.
