Systematic Development and Comparison of Concepts for an Automated Series-Flexible Trickle Winding Process

机译：系统的开发和自动串联柔性Tri流绕线过程的概念比较

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The electrification of the automotive powertrain leads to new challenges for the production of electric drives. The resulting requirements for efficiency and power density of electric traction drives are currently not sufficiently fulfilled. The stator as an essential component of an electric drive generates the magnetic rotary field. By virtue of this effect the stator winding has a great influence on the performance and efficiency of an electric drive. The “NeWwire” project, as a starting point of this article, is concerned with the development and design of a novel automated winding process for the production of effective stator windings in order to achieve the required improvement in efficiency and performance. Therefore the so-called trickle winding process which is currently mainly carried out manually is to be automated. The goal is the reproducible filling of stator grooves with high copper fill factors in the shortest possible cycle times. To achieve this goal, concepts for suitable plants were developed with the help of the development method according to VDI 2221. At the beginning, the manual trickle winding process was divided into its sub-steps which were examined in detail. By following suitable analogies, solutions for an automated process were found. Finally, possible solution paths of the morphological box were combined to concept ideas. The main focus of the article is on the results of the systematic development steps. For this purpose, functional samples were produced in form of prototypes, their properties analyzed regarding the wire contribution and compared in several test series. The evaluation of these test series closes the main part of the paper.

机译：汽车动力总成的电气化为电动驱动器的生产带来了新的挑战。当前对电动牵引驱动器的效率和功率密度的最终要求尚未得到充分满足。定子作为电驱动器的基本组成部分，会产生旋转磁场。由于这种作用，定子绕组对电驱动的性能和效率有很大的影响。作为本文的起点，“ NeWwire”项目涉及用于生产有效定子绕组的新型自动绕组工艺的开发和设计，以实现所需的效率和性能改进。因此，目前主要手动进行的所谓的滴流卷绕过程将是自动化的。目标是在尽可能短的循环时间内以高铜填充系数可重复填充定子凹槽。为了达到这个目标，根据VDI 2221的开发方法，开发了适用于植物的概念。开始时，手动滴流卷绕过程分为几个子步骤，并对其进行了详细研究。通过遵循适当的类比，找到了自动化过程的解决方案。最后，将形态学盒子的可能求解路径组合到概念思想中。本文的主要重点是系统开发步骤的结果。为此，以原型形式生产功能性样品，分析其有关导线作用的特性，并在几个测试系列中进行比较。这些测试系列的评估结束了本文的主要部分。

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《International Electric Drives Production Conference》|2018年|1-7|共7页
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Maximilian Halwas; Philipp Ambs; Michael Marsetz; Christopher Baier; Waldemar Schigal; Janna Hofmann; Jürgen Fleischer;
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Windings; Wires; Stator windings; Prototypes; Fasteners;

机译：绕组;电线;定子绕组;原型;紧固件;

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Systematic Development and Comparison of Concepts for an Automated Series-Flexible Trickle Winding Process

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