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V diplomskem delu je predstavljeno iskanje tehnoloških rešitev, potrebnih za avtomatizacijo obdelovalnega procesa zvijanja odcepov statorja. V prvem delu je predstavljen stator, izdelovalni postopki statorja in njegova vgradnja v alternator, teorija preoblikovanja, postopek upogibanja ter teoretični izračun sile upogibanja. Pri teoretičnemu izračunu sile upogibanja smo enačbe prilagodili za naš primer, torej za upogibanje žic, saj te še ne obstajajo oziroma v literaturi niso dostopne. V drugem delu naloge se posvetimo pridobivanju podatkov za potrebe tehničnih zahtev izdelave naprave za upogibanje alternatorskih statorskih odcepov. Podatke smo pridobili z meritvami sil upogibanja in jih nato primerjali s teoretičnimi izračuni. Ugotovili smo, da se rezultati med seboj precej razlikujejo, zato smo izpostavili dejavnike, ki v praksi vplivajo na rezultate. Ugotovitve diplomskega dela bodo v prihodnje služile pisanju tehničnih zahtev za novo napravo. Podali smo tudi nekaj predlogov za avtomatizacijo delovnega mesta. This diploma thesis represents the search for technological solutions, which are necessary for the automatization of the manufacturing process of bending branches on stators. In the first part of the paper, we present the stator, the processes of its manufacturing and its installation into an alternator. This is followed by the theory of metal forming and the theoretical calculation of the bending force. In the theoretical calculation of the bending force, we have adjusted the equation for wire bending, because such equations are otherwise either non-existent or not available in the literature. In the second part of the thesis, we focused on obtaining the data needed for the technical requirements. We carried out measurements of the bending force and then compared the results with the results of the theoretical calculations. As there were considerable discrepancies between the obtained results, we have highlighted the factors which, in practice, influence the results. In the future, the findings of the thesis paper can be used for the purpose of writing engineering requirements for a new machine. We have also provided some suggestions for the automatization of the workplace.

Navitje kolesnega elektromotorja je občutljivo na vodo. Epoksidna smola, v katero je zalit stator kolesnega elektromotorja, je nagnjena k pokanju. Razpoka omogoči vodi dostop do navitja. V kolikor voda pride do navitja, se zgodi preboj, ki povzroči nedelovanje motorja. Stator ovijemo v zunanjo zaščito in s tem vodi preprečimo dostop v razpoke. Namen diplomske naloge je določiti vse potrebno za ovitje statorja v zaščitno folijo. Testirali smo dva različna tipa folije. Pri jekleni foliji smo določili ustrezno lepilo, parametre mreženja lepila in izvedli prednapetje folije. Rezultate smo vrednotili z meritvami odprtega tokokroga, kjer smo se osredotočili na izgube zaradi induciranih vrtinčnih tokov. Pri ovitju statorja v polimerno termoskrčljivo folijo smo določili pripravo površine statorja, dodajanje epoksidnega lepila, pritisno silo v obliki ukalupljanja statorja in parametre mreženja lepila. Folijo smo testirali s testom toplotnega šoka, opazovali smo interakcije različnih materialov. Rezultati so pokazali, da je jeklena folija za ovijanje procesno zelo zahtevna, izgube zaradi vrtinčnih tokov pa so še sprejemljive. Polimerna folija se je izkazala za bolj primerno izbiro, pritisna sila je zagotovila dobro adhezijo med folijo in statorjem. Testiranje ni pokazalo večjih nepravilnosti, folija ni bila poškodovana in je prestala test. The winding of an in-wheel electric motor is water sensitive. Epoxy resin, with which the stator of an in-wheel motor is casted, is prone to cracking. The crack allows water to access the winding. In case water reaches the winding, an electrical breakdown occurs, that causes the engine to malfunction. To prevent water from entering into the cracks, the stator is wrapped with external protection. The purpose of the thesis is to determine all requirements needed to perform foil wrapping of the stator. We tested two different types of foil. For the steel foil we determined the proper glue for the application, curing parameters of the glue and prestressed the foil. We evaluated the results by open circuit measurements, where we focused on the induced eddy current losses. For the polymer heat shrinking foil we determined the surface preparation of the stator, the addition of epoxy glue, the compressive force in form of a stator mold and the curring parameters of the glue. We tested the foil with a heat shock test, where we observed interactions between different stator materials. The results for the steel foil showed that the wrapping process is very demanding, but on the other hand the eddy current losses were still manageable. The polymer heat shrinking foil proved to be a better choice, the compressive force ensured good adhesion between the foil and the stator. The testing results didn't show larger irregularities, the foil wasn't damaged and passed the test.