Simulation of orthocyclic windings using the linear winding technique

Conference contribution
(Conference Contribution)


Publication Details

Author(s): Bönig J, Bickel B, Spahr M, Fischer C, Franke J
Publisher: Institute of Electrical and Electronics Engineers Inc.
Publication year: 2015
ISBN: 9781467375115


Abstract


A continuously rising number of electric vehicle licensing is mentioned since the last few years in Germany. For a cost-efficient production of electrical engines in first-class quality and in sufficient quantity, it is indispensable to understand the process of coil winding. Thereby, the prediction of wire behavior is one of the key challenges. Therefore, a detailed model is built to investigate wire behavior during the linear winding process. The finite element based simulation tool LS-DYNA serves as explicit dynamics tool. The tool works with an explicit time integration method for time discretization. To represent the high dynamic process of winding within this simulation, dynamic influences such as rotational speed or acceleration of the coil body are definable. Within process simulation, the given boundary conditions are applied to the model. The non-linear material properties of the wire are validated under scrutiny by a tensile test and by values out of datasheets in previous research work. Simulation results of orthocyclic windings using the linear winding technique are presented within this paper. The dynamic simulation model is validated by experiments using the caster angle of the wire guide as reference parameter. The caster angel rises during the winding process of the first layer until the wire jumps to the next layer. Hence, it is possible to identify the maximum caster angle and match the simulation value against the experiment value. The travel profile of the wire guide is identified as extremely important to generate an orthocyclic winding. Another substantial part is the wire fixation respectively the geometry to support the first winding offset from winding one to winding two. Results of orthocyclic windings are simulated with and without grooves on the coil body surface and demonstrate the positive influence of grooves for an accurate orthocyclic winding picture.



FAU Authors / FAU Editors

Bickel, Benjamin
Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik
Bönig, Jochen
Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik
Fischer, Christian
Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik
Franke, Jörg Prof. Dr.-Ing.
Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik
Spahr, Michael
Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik


How to cite

APA:
Bönig, J., Bickel, B., Spahr, M., Fischer, C., & Franke, J. (2015). Simulation of orthocyclic windings using the linear winding technique. In Proceedings of the 5th International Conference on Electric Drives Production, EDPC 2015. Institute of Electrical and Electronics Engineers Inc..

MLA:
Bönig, Jochen, et al. "Simulation of orthocyclic windings using the linear winding technique." Proceedings of the 5th International Conference on Electric Drives Production, EDPC 2015 Institute of Electrical and Electronics Engineers Inc., 2015.

BibTeX: 

Last updated on 2019-18-07 at 07:21