Explicit dynamics process simulation of linear coil winding for electric drives production

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: 2014
ISBN: 9781479950089


Abstract


Slowly but steadily, more and more electric vehicles push onto the consumer market. 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 the 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. To represent the high dynamic process of winding within this simulation, some first adaptions have to be made. This means, that 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 material properties of the wire under scrutiny are validated by a tensile test and by the values out of datasheets in previous research. In order to achieve the best convergence, different contact algorithms are selected for each individual contact behavior. Furthermore, specific adjustments to the mesh are necessary to gain significant results. State of the art in coil winding is an experimental procedure, which delivers adequate process parameters and, thus, expertise in winding technology. Nevertheless, there are a lot of different, interacting parameters, which have to be optimized in terms of boundary conditions. The simulation model of winding process, in which varying parameters can be optimized pertaining to the optimal winding result, calls for extensive research in this field. The generated model enables the user not only to influence the process parameters but also to modify the geometry of a winding body. To make the simulation scientifically sound, it is validated by previous experiments and simulations



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. (2014). Explicit dynamics process simulation of linear coil winding for electric drives production. Institute of Electrical and Electronics Engineers Inc..

MLA:
Bönig, Jochen, et al. "Explicit dynamics process simulation of linear coil winding for electric drives production." Proceedings of the 2014 4th International Electric Drives Production Conference, EDPC 2014 Institute of Electrical and Electronics Engineers Inc., 2014.

BibTeX: 

Last updated on 2018-29-11 at 13:50