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FE-Based Simulation of Hairpin Shaping Processes for Traction Drives

机译：基于有限元的牵引传动发夹成型过程仿真

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Based on the present change in mobility, there are novel requirements on production technologies of electric drives regarding process reliability, ability for automation, productivity as well as mechanical and electric filling factors. Providing significant advantages compared to conventional winding technologies, the hairpin technology combined with the usage of flat copper wire is a promising opportunity to fulfill the upcoming standards. Hence, the AnStaHa project aims the qualification of the hairpin technology for application in mass production. In spite of numerous advantages, the application of the hairpin technology also shows weaknesses. In particular, the shaping of hairpins is considerably more complex than corresponding process sequences of other winding technologies. The main reasons for this are the rectangular cross section and resulting directional properties of flat copper wires, significant springback effects as well as process-related damage of the wire insulation. Therefore, basic knowledge about the deformation behavior of the wire is required for process dimensioning within the context of system design. This paper handles the numerical simulation of hairpin shaping using the commercial finite element software suite Abaqus FEA. The FE-based approach is validated by experiments for different geometries and includes the complete forming process of hairpins, which is considered to be implemented in two following steps - U-bending and 3-D-shaping. Because the numerical analysis takes wire springback into account, the results can be used for a digital evaluation of hairpin shaping processes during the period of system design.
机译：基于当前的移动性变化，对电驱动器的生产技术提出了新的要求，涉及过程可靠性，自动化能力，生产率以及机械和电气填充系数。与传统绕组技术相比，发夹技术与扁铜线的使用相比具有明显的优势，这是满足即将到来的标准的有希望的机会。因此，AnStaHa项目旨在对发夹技术进行鉴定，以用于大规模生产。尽管有很多优点，但发夹技术的应用也显示出缺点。尤其是，发夹的造型比其他绕线技术的相应处理顺序要复杂得多。造成这种情况的主要原因是矩形横截面以及扁平铜线的定向特性，明显的回弹效应以及与工艺相关的导线绝缘层损坏。因此，在系统设计范围内进行工艺尺寸确定时，需要有关导线变形行为的基本知识。本文使用商业有限元软件套件Abaqus FEA处理发夹造型的数值模拟。基于有限元的方法已通过针对不同几何形状的实验验证，并且包括发夹的完整成型过程，该过程被认为可以通过以下两个步骤实现-U形弯曲和3-D形变。由于数值分析考虑了导线回弹，因此该结果可用于在系统设计期间对发夹成型过程进行数字评估。

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