Resource-efficient, innovative coil production for increased filling factor

Manufacturable Edgewise Winding Solutions Considering Parallel Slot and Parallel Tooth Stator Structures

“…Hairpin and edgewise winding aspect ratio difference Additionally, harsh environments where windings will experience significant NVH can be problematic for bending failure in edgewise windings [18]. Deformation and mechanical stress negatively impacts other material properties such as breakdown voltage, thermal resistance, and expected lifetime [19]. Degradation of the insulation due to mechanical or thermal sources acts to reduce mean time to failure, as machine lifetime tends to be dictated by thermal performance.…”

“…A key factor in edgewise manufacture is ensuring manufacturing variability has minimal impact on turn-to-turn contact, which is critical to thermal conduction. Variation in turn-to-turn contact leads to lower heat transfer and can cause winding hotspots [19]. Prefabricated conductors tend to be structured such that good thermal contact is achieved between coils, and hence the thermal performance can be improved.…”

Investigation of the Forming Behavior of Copper Wires for the Compaction of Windings for Electric Machines

“…Here, the cross- sections can often be varied depending on their position in the stator slot, also round or rectangular wires are used as an incoming semi-finished product. [17][18][19][20][21] For the numerical analysis, the input material parameters are essential. Detailed investigations for round enameled copper wires were carried out by Komodromos [22] with a focus on the linear winding process, and the obtained density, Young's modulus and Poissons's ratio are used in this work.…”