AUTO-MEA · Project

Automated Coil Winding System That Makes Electric Motors Smaller and Lighter

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Electric motors are getting faster and more powerful thanks to new semiconductor chips, but the copper coils inside them haven't kept up — they're still wound the old way, leaving gaps and wasting space. Imagine trying to pack spaghetti neatly into a jar versus just shoving it in; the tighter you pack it, the more power you get from the same size motor. This project built a programmable machine that automatically shapes and welds coils in 3D, packing them tighter and making them work at frequencies above 1 kHz without overheating or breaking down. The main target is aerospace, where every gram of motor weight matters.

By the numbers

EUR 1,095,030

EU research investment in automated winding technology

>1 kHz

Target fundamental operating frequency for electrical machines

2 partners

Consortium size (1 university + 1 industrial partner)

50%

Industry participation ratio in the consortium

Total project deliverables including 2 demo setup deliveries

The business problem

What needed solving

Electric motors are being pushed to operate at higher frequencies (above 1 kHz) thanks to new SiC and GaN semiconductor drives, but current coil winding methods cannot keep up. Manual or conventional winding produces coils with poor copper fill factors, large end windings, high thermal resistance, and insulation that degrades rapidly under fast voltage switching — leading to motor failures, oversized designs, and wasted energy.

The solution

What was built

The project built and delivered a flexible, programmable coil fabrication setup (delivered in 2 parts) capable of producing 3D-formed coil shapes optimized for high-frequency operation. The system includes automated coil insertion and welding strategies to form complete winding systems, specifically targeting aerospace wound components.

Audience

Who needs this

Aerospace electric propulsion manufacturers needing lighter, more compact motorsEV and e-mobility drivetrain companies pushing motor power densityHigh-speed industrial motor and generator manufacturersCompanies integrating SiC/GaN drives experiencing winding insulation failuresCoil winding equipment manufacturers looking for next-generation technology

Business applications

Who can put this to work

Aerospace & Aviation

enterprise

Target: Electric propulsion system manufacturers and aircraft component suppliers

If you are an aerospace component supplier struggling with heavy, bulky electric motors that eat into payload capacity — this project developed a flexible, programmable coil fabrication system that produces compact 3D-formed windings with high fill factors for operation above 1 kHz. The automated process replaces manual winding, reducing variability and improving reliability for flight-critical components. The system was built with 1 industrial partner and delivered as a working setup.

Electric Vehicle & E-Mobility

mid-size

Target: EV motor manufacturers and tier-1 drivetrain suppliers

If you are an EV drivetrain manufacturer dealing with motor size and weight constraints in tight vehicle packaging — this project's automated winding technology delivers higher copper fill factors and lower AC losses at high frequencies. Motors wound with this system can be smaller and lighter for the same power output. The programmable setup handles different coil geometries, which means one machine line can serve multiple motor designs.

Industrial Motor Manufacturing

any

Target: Producers of high-speed motors, generators, and transformers

If you are a motor manufacturer losing units to insulation failure caused by fast-switching wide-bandgap (SiC/GaN) drives — this project addressed exactly that problem. The coil fabrication system produces windings with proper insulation designed to withstand fast voltage edges, plus automated welding for consistent connections. The 2-partner consortium delivered a flexible programmable setup validated for high-frequency operation.

Frequently asked

Quick answers

What would it cost to adopt this automated winding technology?

The project operated on a EUR 1,095,030 EU budget across 2 partners over 3 years — this gives a sense of R&D investment scale. Licensing or purchasing the programmable setup would require direct negotiation with the University of Modena and their industrial partner. Based on available project data, no commercial pricing has been published.

Can this scale to industrial production volumes?

The project delivered a 'flexible programmable setup' (in two parts), which indicates a functional prototype rather than a full production line. The system is designed to be programmable for different coil shapes, which supports flexible manufacturing. Scaling to high-volume production would likely require further engineering and integration work.

What is the IP situation and can we license this?

As an EU-funded RIA project, intellectual property typically stays with the consortium partners — the University of Modena and their industrial partner. Licensing arrangements would need to be negotiated directly. The technology covers automated 3D coil forming, insertion, and welding strategies.

Does this work with existing motor designs or only new ones?

The system is described as 'flexible' and 'programmable' for different 3D coil shapes, suggesting it can be adapted to various winding configurations. However, it was specifically designed for high-frequency operation above 1 kHz with wide-bandgap semiconductor drives. Compatibility with your specific motor design would need to be assessed case by case.

How does this handle the insulation degradation problem from fast-switching drives?

This is a core problem the project addressed. Fast-switching SiC and GaN semiconductors cause rapid voltage edges that degrade conventional coil insulation. The project developed winding methods with appropriate insulation to withstand these conditions, combined with high fill factors to reduce thermal resistance and losses.

What is the timeline to implement this in our facility?

The project ran for 3 years (2019-2022) to develop and deliver the setup. Based on available project data, integration into an existing production facility would depend on your motor specifications and volumes. The programmable nature of the setup suggests it can be configured for different applications, but timeline specifics are not published.

Consortium

Who built it

This is a lean, focused consortium of just 2 Italian partners — the University of Modena (a strong engineering school) and 1 industrial partner, giving a 50% industry ratio. The all-Italian setup means tight collaboration but limited cross-border validation. The EUR 1,095,030 budget is modest, typical for a targeted manufacturing R&D effort rather than a large-scale demonstration. The presence of an industrial partner suggests the technology was designed with real manufacturing constraints in mind, though the small consortium size means commercial readiness will require additional industry engagement beyond the project.

UNIVERSITA DEGLI STUDI DI MODENA E REGGIO EMILIACoordinator · IT

How to reach the team

The coordinator is the University of Modena and Reggio Emilia (Italy). SciTransfer can facilitate an introduction to the research team.

Order a report on this consortium See UNIVERSITA DEGLI STUDI DI MODENA E REGGIO EMILIA profile →

Next steps

Talk to the team behind this work.

Want to explore how this automated winding technology fits your motor production? SciTransfer can arrange a direct briefing with the research team and help evaluate licensing options.

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