Methodology for the Mechanical Characterization of Rectangular Winding Wire in the Context of Electric Mobility

Wirth, Felix; Vitzthum, Simon; Gerner, Johannes; Koprivc, Aleksander; Hausmann, Ludwig; Fleischer, Jürgen

doi:10.1109/edpc60603.2023.10372157

Cited by 2 publications

(3 citation statements)

References 23 publications

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“…This value is consistent with the FE simulation and analytic calculation results presented in Table 2. In addition, the Young's moduli obtained fall within an acceptable range, matching those of previous experimental studies [22]. However, the provided results of the Young's moduli in the study only show the variation of the property measured under a 10 -4 s -1 strain rate condition; therefore, the rate-dependent uncertainty is not considered.…”

Section: (A) (B) Figure 2 Tensile Simulation Boundary Conditions and ...supporting

confidence: 82%

“…The mechanical properties were obtained by the FEM inverse method, optimizing the material model parameters to coincide with the experimental data. In particular, the reported Young's moduli of hairpin coils in a previous study range from 84 to 98 GPa [10], [22]. Even though the applied strain rate of the tensile test is considered to be under static conditions, the elastic property varies widely.…”

Section: Introductionmentioning

confidence: 99%

“…A polymer-based insulator material is coated on the copper conductor surface. This insulator significantly affects the experimental results of the tensile tests [11], [22]. The forming conditions are based on the combined properties of the insulator and conductor.…”

Section: Introductionmentioning

confidence: 99%

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Evaluation of Mechanical Properties Considering Uncertainties for Hairpin Coils in Electric Vehicle Motor Manufacturing

Shim,

Kim,

Kim

et al. 2024

IEEE Access

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The rising demand for electric vehicles (EVs) underscores the need for enhancing electric motor efficiency. Utilizing hairpin coils with a rectangular cross-section has emerged as an alternative approach to increase conductor density in motor stator slots. However, the manufacturing process for hairpin coil motors presents challenges such as springback, which stems from wire shaping processes such as leveling and bending with plastic deformation. These challenges are closely tied to mechanical properties of the Young's modulus and yield stress. This study investigates uncertainties in mechanical property evaluation using a combination of tensile tests, analytic solutions, numerical simulations, and a present double-sided four-point bending method. The results show significant variations in the Young's modulus, which affect the determination of yield stress in tensile tests. It has been revealed that in order to obtain stable mechanical properties of hairpin coils in tensile tests, the conditions should be restricted to a very slow strain rate, slower than 10 -3 s -1 . To address this, this study introduces an alternative method that combines double-sided four-point bending and tensile tests, allowing for the acquisition of Young's modulus without prior information on material properties. This approach reduces uncertainties in determination of the mechanical properties with much less time cost.

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Section: (A) (B) Figure 2 Tensile Simulation Boundary Conditions and ...supporting

confidence: 82%

Section: Introductionmentioning

confidence: 99%

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Evaluation of Mechanical Properties Considering Uncertainties for Hairpin Coils in Electric Vehicle Motor Manufacturing

Shim,

Kim,

Kim

et al. 2024

IEEE Access

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Model-based closed-loop process control for the manufacturing of hairpin coils

Wirth,

Hausmann,

Fleischer

2024

Prod. Eng. Res. Devel.

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As a consequence of the increasing market share of hybrid and all-electric mobility solutions, there is a need for robust manufacturing technologies that enable the efficient production of powerful electric traction motors in automotive industry. In the context of high-quality distributed stator windings, the so-called hairpin technology already meets the automotive demand regarding productivity – but process reliability is still limited by variations in the mechanical and geometric properties of the enameled rectangular copper wire leading to different springback effects within the forming processes. Against this background, a model-based closed-loop process control for the sequential tool-bound bending of hairpin coils is introduced and validated in this paper.

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Methodology for the Mechanical Characterization of Rectangular Winding Wire in the Context of Electric Mobility

Cited by 2 publications

References 23 publications

Evaluation of Mechanical Properties Considering Uncertainties for Hairpin Coils in Electric Vehicle Motor Manufacturing

Evaluation of Mechanical Properties Considering Uncertainties for Hairpin Coils in Electric Vehicle Motor Manufacturing

Model-based closed-loop process control for the manufacturing of hairpin coils

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