In recent years, the so-called hairpin technology has become widely accepted for the manufacturing of high-quality distributed stator windings used in automotive traction motors due to its advantageous productivity compared to other winding technologies. However, the time-consuming and resource-intensive ramp-up of the key processes of hairpin coil bending, assembly and joining, as well as widening and twisting of the open coil endings remains a major challenge. Although the machine and equipment manufacturing industry has already installed many series production lines for stators with hairpin winding within the last few years, the process parameters for twisting and widening, which are mainly based on the stator design and the rectangular wire forming properties, are often still determined by extensive experimental test series. In addition, a scientific approach for calculating the necessary tool motions to speed up the process commissioning has not been published in detail yet. Against this background, a generalized geometric wire model for the calculation of tool motions for the twisting process of stators with hairpin winding is presented in this paper and validated with both finite element simulations and experimental results.


    Access

    Check access

    Check availability in my library

    Order at Subito €


    Export, share and cite



    Title :

    Calculation of Process Parameters for the Twisting of Stators with Hairpin Winding


    Contributors:


    Publication date :

    2023-11-29


    Size :

    2314487 byte





    Type of media :

    Conference paper


    Type of material :

    Electronic Resource


    Language :

    English



    Flexible Twisting Process of Stators with Hairpin Winding

    Hausmann, Ludwig / Wirth, Felix / Fleischer, Jurgen | IEEE | 2022


    Image-Based Wire Position Detection for a Flexible Twisting Process of Hairpin Stators

    Schroder, David / Hausmann, Ludwig / Kobler, Florian et al. | IEEE | 2024


    Produktionsprozess eines Hairpin-Stators

    Kampker, Achim / Heimes, Heiner Hans / Kawollek, Sebastian et al. | TIBKAT | 2020


    Opportunities of Model-Based Production-Oriented Design of Stators with Hairpin Winding

    Hausmann, Ludwig / Wirth, Felix / Fleischer, Jurgen | IEEE | 2020


    Experimental Investigation of a New Manufacturing Technology for Hairpin Stators with Litz Wires

    Riedel, Andreas / Kuhl, Alexander / Franke, Jorg et al. | IEEE | 2022