Welcome

to
ELMOTEC STATOMAT
Vertriebs GmbH
 Corporate Profile
ELMOTEC-STATOMAT with World Headquarters in
Karben, Germany creates a world-wide sales and distribution network
for assembly lines and installations for the production of stators and cordsets

ÎHigly qualified engineering designers, mechanical engineers and

electronics specialists stand behind our product program
ÎWe grant you safety, cost-effectiveness and reliability
ÎFor semi-automated stand-alone machines
ÎFor fully automated assembly lines

Production of Production of
Stators und Alternators Electric Cordsets
 Corporate Profile
Our machines are the most modern and technically advanced machines
on the market, our customers have made us today‘s market leader

ÎABB ÎMANNESMANN
ÎELEKTROLUX ÎDEMATIC
ÎEMBRACO ÎSEW
ÎEMERSON ÎSIEMENS
ÎFLENDER ÎVALEO
ÎATB ÎVERDICHTER
ÎZANUSSI ÎWEG
 Corporate Profile

We pursue a consistent policy of innovative thinking and action

Î Rationalization
Î Quality optimization

WeÎguarantee
Close contact with our
optimal customers
organization of all business processes
Î Personal contact with local suppliers
from
Î Modern 100-Mbit Ethernet-Network for the control of plant
operations
customer inquiry Î final delivery
Î Object-oriented software solution for purchasing, sales, design,
manufacture and assembly, warehousing and disposition
 History
1949

The STATOMAT company is founded

Founders: Messrs. Balzer and Dröll

 History
1949 - 1957

Manufacturing of:

Î Stator Slot Insulating Machines

Î Winding Head Lacing Machines

 History
1958

Z-Winder
1st Generation
of Winding Station with
Coil Winding and
Compulsory Coil Stripping
Inserting Machines
 History
1967

A new plant
is occupied
in
Niederdorfelden
 History
1971

M-Winder
2nd Generation
of Winding Station with
Coil Winding and
Elektromechanical Drive
Inserting Machines
 History

1979 - 1982

WORLD-NEWNESS

Î Fully automated compressor production line

Î Modular microprocessor-controlled system

 History

1982

Opening of a new buiseness-field

Î Fully Automated Electric Cordset

Processing Line for 2- and 3-Core cables
 History

1992
ELMOTEC is founded

ity
ctiv
d u
o
Pr

Î Manufacturing of special machines for the

production of electrical motors
Safe
ty
relia
E co n o m y bilit
y
 History

1994/95

A-Winder
3rd Generation
of PC-Controlled Winder
Coil Winding and
Windows Operating System
Inserting Machines
 History

1995

ELMOTEC
occupies
its new plant
in Karben
History
 History

1998

ELMOTEC GmbH acquires the

company STATOMAT GmbH
Shareholding directors of the two companys are:
Î Mr. Dieter Kleinschmidt
Î Mr. Sadik Sadiku
 History

1999

Manufacturing of :

Î Fully Automatic Microprocessor-controlled

electromechanical Production Lines
 History

2000

ELMOTEC-STAMOTAT
is the world‘s leading supplier
of specialized machines and systems
for electrical motor production
 Region and
Subsidiary Companies
 Region and Subsidiary Companies
Subsidary Companies Partner Companies

USA BRAZIL

INDIA UK

ƒ
 Region and Subsidiary Companies
Agencies
AUSTRALIA FRANCE HONG KONG IRAN

ITALY TAIWAN KOREA CZECH REP.

ƒ
 Number of Personnal
Staff

250

200

ELMOTEC-STATOMAT
ELMOTEC-STATOMAT

ELMOTEC-STATOMAT
150
Statomat
100 Elmotec

50

0
1993 1994 1995 1996 1997 1998 1999 2000
 Share of the market
Share of the market, worldwide

45% Elmotec-Statomat
Others
55%
 Turnover
Share of turnover after regions

Germany
15%
Europe
World
60%
25%
 Turnover
Turnover Rate
100
100 90
80
80

ELMOTEC-STATOMAT

ELMOTEC-STATOMAT

ELMOTEC-STATOMAT
60
Statomat
40 Elmotec

20

0
1993 1994 1995 1996 1997 1998 1999 2000
 Product Program
Machines and Systems for Machines and Systems for
Production of Electric Motors Production of Electric Cordsets

Machines and Systems for Machines and Systems for Machines and Systems for
Serial Manufacturing Small-Series Manufacturing 2- and 3-core Cordsets

Stators Alternators Stators

Production Steps:
Stack Making * Insulating * Winding * Inserting
Forming * Final Forming * Lacing * Testing
End
 Product Program
Electrical Motor Technology

Î Machines and Installations for Manufacturing of Stators

and Alternators
Î Stand-alone Machines
Î Interlinked Machines
Î Automatic Systems
Î Fully Automatic Production Lines

Serial Small-Series
Manufacture Manufacture
 Product Program
Electrical Motor Technology
Serial Manufactur

Stack Making of Stators or Rotors

Î Automatic stack making of loose laminations from a magazine
Î Automatic lamination thickness compensation
Î Top lamination turning, punch ridge inside
Î Welding, cleating or riveting
Î Isolating of stator slots
Î Rotor stack twisting
Î Shaft or dummy mandrel pressing in
 Product Program
Electrical Motor Technology
Serial Manufacture

Insulating of Stator or Rotor Slots

Î Manufacturing of insulating sleeves, with or without cuffs

Î Extension unit for warm forming of insulation sleeve cuffs

Î Extension unit for wedge making of stator or rotor slots

 Product Program
Electrical Motor Technology
Serial Manufacture

Winding of Concentric Coil Groups

Î Winding of coil groups in a coil-transfer tool

 Product Program
Electrical Motor Technology
Serial Manufacture

Winding of coil groups in wave-shape

Î Cross-free winding of wave-shaped coils >distributed (split) or

non-distributed (standard)< in a coil-transfer tool
 Product Program
Electrical Motor Technology
Serial Manufacture

Coil Inserting Machines

Î Inserting of winding and closing of slots by a wedge strip

 Product Program
Electrical Motor Technology
Serial Manufacture

Coil Winding and Inserting Automatic Machines

Î Winding of coil groups „concentric or in wave shape“ into an
inserting tool
Î Automatic inserting of winding
Î Closing of slots by means of wedge strips
Î Linking of individual stations by a indexing table or linear system
Î Linear system with circulating transport pallets or movable
manipulator
Î Automatic loading and unloading via a gripper system
 Product Program
Electrical Motor Technology
Serial Manufacture

Intermediate Forming Machines and Devices

Î Intermediate forming of winding

Î Double-sided intermediate forming of winding
Î Simultaneous intermediate forming of winding and final
forming of winding heads to inner/outer diameter and height
Î Tools can be fitted with supporting fingers in order to
protect the cuffs of the insulating sleeves
 Product Program
Electrical Motor Technology
Serial Manufacture

Winding Head Final Forming Machines

Î Double-sided final forming of winding heads to

inner/outer diameter and height
Î Tools can be fitted with supporting fingers in order to
protect the cuffs of the insulating sleeves
 Product Program
Electrical Motor Technology
Serial Manufacture

Winding Head Lacing Machines and Systems

Î One- or double-sided lacing of winding heads
Î One- or double-sided lacing head
Î Additional lacing cord knotting unit
 Product Program
Electrical Motor Technology
Serial Manufacture

Automatic Impregnation Systems for Stators or Rotors

Î Automatic impregnation of winding

Î Interlinkage of single working stations either with
Î Indexing table or linear system
 Product Program
Electrical Motor Technology
Serial Manufacture

Stator Testing System

Î Testing of single or three phase stators

 Product Program
Electrical Motor Technology
Small-Series Manufacture
 Product Program
Electrical Motor Technology
Small-Series Manufacture

Forming and Cutting Device for Stator and Rotor Insulations

Î Mechanical production of insulating sleeves >with or without cuffs<

Î Mechanical production of wedge strips
Î Manual pushing of sleeves into the stator or rotor slots
 Product Program
Electrical Motor Technology
Small-Series Manufacture

Coil Winding Machines for the Production of Concentric Coils

Î Winding of coil groups >with or without coil connection<

Î Rotating winding former, horizontally or vertically adjustable

with a wire layering unit
 Product Program
Electric Motor Technology
Small-Series Manufacture

Coil Inserting Machines

Î Inserting of coil groups

Î Closing of slots by means of wedge strips
Î Coil groups and wedge strips will be positioned manually and then
inserted simultaneously
 Product Program
Production of Electric Cordsets
 Product Program
Production of Electric Cordsets

Electric Cordset Production Unit, Basic Component

Î Cordset production unit designed with all equipment

needed to crimp a plug bridge to the leads of the cable

Production Steps:
Sheath Stripping * Lead Cleaning * Lead Positioning * Lead Spreading
Lead Forming * Insulation Stripping * Corrective Cutting
Checking of Lead Position * Color Check * Crimping of Plug Bridge
Lead Pull-Off Check
 Product Program
Production of Electric Cordsets

Fee
ding
S
5m/ peed
Mac s
Extension of Cordset Production Unit by hine
Cyc
l
Cable Unrolling, Cutting to Length 2s e Time

Î Automatic withdrawn of the cable from the cable reel

Î Cable is cut to length and insulation stripped.- Patented!

Î Cable is positioned in transfer clamps

 Product Program
Production of Electric Cordsets

Extension of Cordset Production Unit by

Crimping of Contacts and Connectors

Î Crimping of contacts and plug connectors on the leads

Î Patented cutting and stripping unit
Î Correction cut on the copper tips
Î Process-security is guaranteed by an effective crimp quality
control monitoring system
 Product Program
Production of Electric Cordsets

Extension of Cordset Production Unit by

Assembling of Protective Cups

Î Assembling of protective cups as per chosen type of connection

Î Feeding of protective cups in proper position out of a large-volume
sorting device
Î Checking of protective cups by a sensor system
 Product Program
Production of Electric Cordsets

Extension of Cordset Production Unit by

Assembling of Plug Half Shells

Î Automatic assembly of plug half shells Clip

or
Sna
Con p-on
nec
nic tion
s o
ra
Ult ing
l d
We

Î National requirements are met

 Product Program
Production of Electric Cordsets

Extension of Cordset Production Unit by

Electrical Checks

Î Electrical checks in a time-controlled transfer line

Î Every desired degree of quality assurance can be achieved
Î Checks are conducted at several stations
Î Cut off of plug when fault is detected
Î Maximum safety quality for each fabricated cable
 Product Program
Production of Electric Cordsets

Extension of Cordset Production Unit by

Depositing of Cables

Î Orderly removal of finished cables

Î Portion-by-portion output on a buffer belt
Î Fully automatic unloading of up to 50 cables into 6 output channels
Î One Operator, who not bound to the machine‘s cycle
 Product Program
Production of Electric Cordsets

Extension of Cordset Production Unit by

Interlinkage with Injection Moulding Machine

Î Removing of cordset out of the transfer clamps

Î Positioning of plug bridge in a locating and transport cassette
Î Feeding of cassette into the Injection Molding Machine
Î Injection molding of plugs
Î Removing of cordset with the molded plug out off the cassette
Î Positioning of cordset in a further transfer device
Î Electrical check and automatic unloading