The electric motor is the main component in an electrical vehicle. Its power density is directly influenced by the winding. For this reason, it is relevant to investigate the influences of coil production on the quality of the stator. The examined stator in this article is wound with the multi-wire needle winding technique. With this method, the placing of the wires can be precisely guided leading to small winding heads. To gain a high winding quality with small winding resistances, the control of the tensile force during the winding process is essential. The influence of the tensile force on the winding resistance during the winding process with the multiple needle winding technique will be presented here. To control the tensile force during the winding process, the stress on the wire during the winding process needs to be examined first. Thus a model will be presented to investigate the tensile force which realizes a coupling between the multibody dynamics simulation and the finite element methods with the software COMSOL Multiphysics®. With the results of the simulation, a new winding-trajectory based wire tension control can be implemented. Therefore, new strategies to control the tensile force during the process using a CAD/CAM approach will be presented in this paper.
Investigations on the tensile force at the multi-wire needle winding process
2017-12-01
1402059 byte
Aufsatz (Konferenz)
Elektronische Ressource
Englisch
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