Coil winding process modelling with deformation based wire tension analysis

Abstract

For electric motors, the stator designs with tooth coils are predominant. Due to their noncircular shape, the tooth coils display a challenge for highly productive winding processes with a low coil resistance. With the use of a process model a prediction of the central process parameters, like the wire tension, can be achieved. This model consists of a wire deformation based multi-body-dynamic simulation, measurements and analytic model aspects which were validated at a test stand. It can be used to optimize controller and actuator designs for wire tension control systems and enables higher winding speeds and winding quality.